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1. Default Screen System Menus Sub Menus Sub Screens A O N 27 Overview Modicon Quantum Hot Standby with Unity Accessing the Screens Use the keys on the keypad to access the system menus and submenus Step Action 1 To access the screens ensure that the key switch is in the unlocked position Ta amp 2 To step down to a lower menu operate one of the following keys ENTER D 3 To return to the previous menu press ESC 28 Overview Modicon Quantum Hot Standby with Unity Understanding the Default Screen Default screen displays the following information port Mode State Bat L PCM The default screen is read only Default Screen Displays Fields Available Options Available Description Default State RUN Application program is running RUN Primary RUN Standby RUN Offline STOP Application program is NOT running STOP Offline No Conf CPU has no application program BatL Indicates health of battery e Steady Battery is low e No message Battery is OK Port USB Indicates that port has activity Modbus Plus
2. LO No application program transfer 1 Application program transfer requested 0 Swaps Modbus port 1 address during switchover 1 Does not swap Modbus port 1 address on switchover System Word Invalidate Keypad is an option that allows a controller to accept or refuse commands SW60 0 from the Hot Standby submenu in the front panel keypad e SW60 0 1 Invalidate Keypad enabled The Modicon Quantum Hot Standby with Unity system refuses all changes from the Hot Standby submenu in the front panel keypad e SW60 0 0 Invalidate Keypad disabled The Modicon Quantum Hot Standby with Unity system accepts all changes from the Hot Standby submenu in the front panel keypad See Setting the Invalidate Keypad Option p 92 114 Configuring a Modicon Quantum Hot Standby with Unity System System Word SWEO0 1 System Word SWE0 2 System Word SW6E0 3 System Word SW6E0 4 Controller A OFFLINE RUN mode e SWE60 1 1 Controller A goes to Run mode e SWE0 1 0 Controller A goes to Offline mode Controller BOFFLINE RUN mode e SWE60 2 1 Controller B goes to Run mode e SW60 2 0 Controller B goes to Offline mode Logic mismatch e SW6E0 3 0 If a logic mismatch is detected Standby forced to Offline mode e SWE60 3 1 Standby operates normally even if a mismatch occurs See Handling Logic Mismatch with Unity Pro p 145 EXEC upgrade e S
3. Number of blinks on Code in hex Error Com Act Indicator Slow steady 0000 requested kernel mode 2 6820 hcb frame pattern error 6822 head control block diag error 6823 mod personality diag error 682A fatal start IO error 682B bad read IO pers request 682C bad execute diag request 6840 ASCII input xfer state 6841 ASCII output xfer state 6842 IO input comm state 6843 IO output comm state 6844 ASCII abort comm state 6845 ASCII pause comm state 6846 ASCII input comm state 6847 ASCII output comm state 6849 building 10 byte packet 684A building 12 byte packet 684B building 16 byte packet 684C illegal IO drop number 6729 984 interface bus ack stuck high 6616 coax cable initialization error 6617 coax cable dma xfer error 6619 coax cable dumped data error 681A coax cable DRQ line hung 681C coax cable DRQ hung 6503 RAM address test error 6402 RAM data test error 6300 PROM checksum error exec not loaded 6301 PROM checksum error 8 8001 kernel PROM checksum error 8002 flash prog erase error 8003 unexpected executive return 192 Additional Information TextiDs TextIDs Textlds define the warning messages written in the diagnostic buffer TextIDs switching from Primary to Offline TextID Warning message 13001 System halt 13002 Remote IO failure 13003 ETH device failure 13004 ETH communication problem 13005 Stop PLC command 1300
4. Lala O 00 Of Till HSB int mee Address Model number module description color code Lens cover open LCD Display here covered by lens cover Key switch Keypad with 2 red LED indicators Modbus port RS 232 RS 485 USB port Modbus Plus port PCMCIA slots A and B Type Il Type III 10 LED indicators yellow for Ethernet communication 11 HSBY fiber optic communications port 12 Restart button 13 Battery user installed Ono RwWN o Note Unity Quantum High End CPUs are equipped with two receptacles A and B in which to install PCMCIA cards PCMCIA is a standard type of memory card 18 Overview Modicon Quantum Hot Standby with Unity Modicon Quantum Hot Standby with Unity System Overview System Components The following graphic shows the components required for a Modicon Quantum Hot Standby with Unity system a PWN o 8 9 10 OM OIEC K AOE L LI ol T aF a eo ULL an l T Ar EEEE KERNI Or E Primary PLC Standby PLC Modicon Quantum Hot Standby with Unity controller with integrated coprocessor Fiber Optic Cable to connect to both controllers Modicon Quantum power supply module Install power supply in first slot for better rack layout Modi
5. TCP IP Ethernet HEEE HEH HH decimal numbers displays IP address IP Address 2 not modifiable TCP IP Ethernet HHH HEH HHH decimal numbers displays Subnet Subnet Mask not modifiable Mask address TCP IP Ethernet HHH HEH HHH decimal numbers displays Ethernet IP IP Gateway not modifiable Gateway address TCP IP Ethernet Ltt tH HH H 4 hexadecimal numbers displays MAC MAC Address read only Medium Access Control address Submenu PLC Communications Modbus Plus Modbus Plus Fields Available Options Available Description Screen Displays Modbus Plus H 1 64 to enter a valid Address modifiable only if the Modbus Plus key switch is in the address unlocked position Modbus Plus State Monitor Link Modbus Plus State Normal Link Sole Station Duplicate address No Token 34 Overview Modicon Quantum Hot Standby with Unity Submenu PLC Communications Serial Port Seriial Port Fields Available Options Available Description Screen Displays Serial Port Mode 232 RS mode 485 Protocol ASCII Protocols available RTU Adr 1 247 Unit address for Modbus switchover Primary 1 119 Standby 129 247 Rate 50 75 110 134 5 150 Baud rate 300 600 1200 1800 2400 3600 4800 7200 9600 19200 bits s Par NONE Parity ODD EVEN DB 7 8 Databits if Protocol is Modbus then RTU 8 or ASCII 7 SB 1 2 Stop
6. General The Modicon Quantum Hot Standby with Unity V2 0 does not support the following modules Model Support Provided 140 NOE 771 00 Module NOT supported in Unity V2 0 140 NOE 771 10 Module NOT supported in Unity V2 0 140 NOE 311 00 Module NOT supported in Unity V2 0 140 NOE 351 00 Module NOT supported in Unity V2 0 140 CHS 110 00 Module NOT supported in Unity V2 0 140 NOA 611 10 Module NOT supported in Unity V2 0 140 NOA 622 00 Module NOT supported in Unity V2 0 140 NOL 911 10 Module NOT supported in Unity V2 0 140 CRP 811 00 Module NOT supported in Unity V2 0 140 HLI 340 00 Module NOT supported in Unity V2 0 44 Compatibility Differences Restrictions Understanding USB Link Restrictions No Hot Standby USB link switchover is not available in a Modicon Quantum Hot Standby with Unity Switchover system because the USB link is connected to only one CPU allowing Unity Pro to through the USB communicate only to this local controller Link Therefore USB cannot be used for transparent access to the Primary controller 45 Compatibility Differences Restrictions Understanding Application Restrictions TimerEventsand Timer events are NOT synchronized in Modicon Quantum Hot Standby with Unity I O Errors applications Schneider Electric recommends not using timer events Note NOT EXCHANGING I O ERRORS If timer events are used I O errors are not exchanged between Primary and S
7. Topic Page Understanding Modicon Quantum Hot Standby with Unity Logic Mismatch 146 Understanding Switchover Behavior during Logic Mismatch 150 Online or Offline Modifications and Logic Mismatch 152 Online Modifications to an Application Program in the Standby and Logic 153 Mismatch Online Modifications to an Application Program in the Primary and Logic 154 Mismatch Offline Modification of an Application Program and Logic Mismatch 155 Switchover Methods and Logic Mismatch 157 Application Program Transfer Method and Logic Mismatch 159 Recommendations for Using Logic Mismatch 160 145 Logic Mismatch Understanding Modicon Quantum Hot Standby with Unity Logic Mismatch Needing Identical Application Programs Defining Logic Mismatch Using the Build Project Function In a fault tolerant redundant system and under normal operating conditions both controllers must load the identical application program also called a logic program The application program is updated every scan by transferring data from the Primary to the Standby Both controllers conduct tests to detect if a mismatch exists between the application programs The following conditions cause a mismatch in the application program a difference between programs e animation tables e comments on variables Note Animation Tables and Comments Both animation tables and comments on variables may be excluded from the mismatch by
8. 152 Logic Mismatch Online Modifications to an Application Program in the Standby and Logic Mismatch Executing the To make online modifications to an application program logic program or project in Procedure the Standby controller follow these steps Step Action 1 Ensure both Primary and Standby controllers are in Run Primary and Run Standby mode Connect to the Primary controller and access the Command Register system bit SWEO 3 Set to 1 the Command Register system bit SW60 3 Connect to the Standby controller Modify online the application program After completing the modifications perform Build Project NIOJ AIO Ensure both Primary and Standby controllers are in Run Primary and Run Standby mode Perform a switchover See Switchover Methods and Logic Mismatch p 157 Note Standby will change to Primary Perform application transfer to Standby Application Program Transfer Method and Logic Mismatch p 159 Connect to the new Primary controller and access the Command Register system bit SW60 3 Set to 0 the Command Register system bit SW60 3 Note Command Register is returned to 0 from 1 Important See Recommendations for Using Logic Mismatch p 160 Reference 153 Logic Mismatch Online Modifications to an Application Program in the Primary and Logic Mismatch Executing the To m
9. 49 IEC Logic Understanding System Scan Time in Modicon Quantum Hot Standby with Unity Systems Effect on System Scan Time The scan time of any Modicon Quantum Hot Standby with Unity system depends on the amount of data transferred Because data must be transferred from Primary to Standby any Modicon Quantum Hot Standby with Unity system always has a higher scan time than a comparable standalone system Note CHANGING FROM LEGACY In legacy systems the CPU performed both e application program project processing e communication transfer In a Modicon Quantum Hot Standby with Unity system in parallel e CPU performs application program processing e Copro performs communication transfer Result Greatly reduced transfer time with Unity 50 IEC Logic Performance A Modicon Quantum Hot Standby with Unity system increases the length of aMAST Considerations scan creating system overhead Note System Overhead System overhead is the time required to copy the application data to the communication link layer The network scan communication between Primary and Standby copros 1 exchanges data between both controllers 2 runs in parallel with the application program A Hot Standby system Most of time the MAST scan hides the network scan 51 IEC Logic Examples However when processing some application programs additional system overhead may occur Examp
10. im 1 2 MBP X MBP E Overview I General F VO objects m Communication Type DIO Bus Peer Cop lt Please choose a link 90 Configuring a Modicon Quantum Hot Standby with Unity System Step Action 6 Select one or both Communication Type e DIO bus Peer Cop 91 Configuring a Modicon Quantum Hot Standby with Unity System Setting the Invalidate Keypad Option Overview Methods for Selecting the Invalidate Keypad Option The keypad is located on the front panel of the Modicon Quantum Hot Standby with Unity 140 CPU 671 60 module Setting the Invalidate Keypad option can disable the Hot Standby submenu PLC Operations Hot Standby See Accessing the Screens p 28 When the Invalidate Keypad option is selected the Hot Standby submenu is read only You may choose to prevent access to the Hot Standby control through the keypad e to avoid the possibility of accidental or malicious state changing e for security or convenience There are two methods for selecting enabling this option Method Used Description Hot Standby tab Select the Invalidate Keypad option in the Hot Standby tab using the Unity Pro software See Using the Hot Standby Tab p 86 Selecting the Invalidate Keypad option requires that the application program be downloaded to the CPU
11. Hot Standby diag off sw60 Hot Standby diag takeover Hot Standby diag run Hot Standby diag plug amp run Hot Standby diag power up 30 Overview Modicon Quantum Hot Standby with Unity Submenu PLC Operations Start Stop Init Start Stop Fields Available Description Init Screens Display Start PLC Press lt ENTER gt to confirm Start Pressing lt ENTER gt starts the controller Stop PLC Press lt ENTER3 gt to confirm Stop Pressing lt ENTER gt stops the controller Init PLC Press lt ENTER gt to confirm Init Pressing lt ENTER gt initializes the controller Submenu PLC Operations Hot Standby Hot Standby Fields Options Available Description Screen Available Displays Hot Standby State PRIMARY Controller serves as Primary State read only STANDBY Controller serves as Standby Off Line Controller is offline Hot Standby Mode RUN steady Controller is active and is either Mode modifiable only serving as the Primary or is capable if of taking over the Primary role if e key switch is needed in the blinking Controller is waiting for configuration unlocked mA OFFLINE steady Controller is taken out of service position idee e invalidate without stopping it or disconnecting it from power Keypad is not s lected e f the controller is the Primary when the Mode stat
12. SWP MB3 BOOL Not used Reserved Description of the output parameters Parameter Data type Meaning HSBY BOOL 1 Hot Standby configuration found 180 Using Modicon Quantum Hot Standby with Unity HSBY EFBs Description REV_XFER Function description Appearance in FBD This EFB allows you to use the Hot Standby function It searches together with other EFBs in the Hot Standby family the configuration of the respective Quantum PLC for the required components These components always refer to hardware that is actually connected Therefore the correct behavior of this EFB on the simulators cannot be guaranteed The EFB REV_XFER provides the option of transferring two 16 bit words from the standby PLC to the primary PLC The two registers transferred by this procedure are Sw62 and 3Sw63 REV_XFER must be called up absolutely in the first section of the project executed The parameter addresses TO_REV1 and TO_REV2 must be in the non transfer area to prevent an overwriting by the Primary PLC Note In the old Concept Hot Standby System these two registers Reverse Transfer Registers are the first addresses in the non transfer area As additional parameters EN and ENO are projected Appearance REV_XFER_Instance REV_XFER Standby_PLC_FirstReg TO_REV1 HSBY HSBY_ConfFlag Standby_PLC_SecondReg j TO_REV2 PRY Primary_PLC_Flag
13. WARNING SWITCHOVER HAZARD If switchover occurs when the Run mode is selected and there is a logic mismatch between the two controllers the Standby assumes Primary responsibilities and starts solving a different application program from the previous Primary e After completing modifications perform application program transfer to ensure controllers contain the same application and remove logic mismatch Failure to follow this precaution can result in death serious injury or equipment damage 151 Logic Mismatch Online or Offline Modifications and Logic Mismatch Modifying Normally once a fault tolerant redundant system is configured programmed and Application controlling its process the system is not shut down not even for periodic Programs maintenance However there may be situations when you may need to make modifications to the application program and continue to control the process The logic mismatch feature allows you to modify application programs online or offline while controlling the process WARNING IMMEDIATE CONTROL OF PROCESS Once a new application program is switched to the Standby the Standby takes control of the process e Ensure that you understand the 1 operation of your process 2 modifications made e Monitor all modifications to the application program Failure to follow this precaution can result in death serious injury or equipment damage
14. Follow these steps Step Action 1 Configure two backplanes with identical hardware and firmware in identical order Connect to a Remote I O RIO drop Establishing the Primary and Standby Controllers p 58 Note Ensure that the fiber optic cable is connected between the controllers Start Unity Pro software and configure the local rack and the Remote I O drop as per your physical configuration After completing Step 3 execute the Build Project command and save your application program Power up and connect to one controller Note The front panel keypad will display No Conf Download your application program and RUN the controller Note The controller will become RUN Primary Power up the other controller Note Application Program Transfer will occur automatically The other controller will become RUN Standby Ensure the Primary and Standby controllers are in RUN Primary and RUN Standby mode 66 Installation and Cabling Preparing to After completing the preceding steps your Modicon Quantum Hot Standby with Switchover Unity system is ready to perform a switchover Perform the switchover using either e Hot Standby submenu on the front panel keypad e Command Register system bit SW60 1 or SW60 2 Note Observing the Switchover If you would like to observe a switchover effect on the I O modules configure the Remote I O RIO drop with a discrete outp
15. e Ensure that both I O maps are identical e Ensure that both configurations are identical Failure to follow this precaution can result in death serious injury or equipment damage Selecting the Standby On Logic Mismatch option allows you to override this default condition Standby going offline If you change the parameter in this field from Offline to Running the Standby remains online if a logic mismatch is detected between the application program of the Standby and the application program of the Primary All data of a section will be fully updated during every scan if the data in the Standby is equal to the counterpart data on the Primary Section data will not be updated if it is not equal to its counterpart on the Primary If the sections are equal on the Primary and the Standby the section data that is updated is e Internal states of Elementary Function Blocks EFBs used in the section For example Timers Counters PID e All Derived Function Block DFB Instance data blocks of each DFB instantiated in the section including nested DFBs 148 Logic Mismatch Updating Global Data in an Application Program With the Logic Mismatch enabled application program global data will be updated with every scan Global data that does not exist on both controllers is not updated The application program s updated global data includes both 1 All declared variables in the Variable Editor 2 All
16. 2 Receives a swap UDP message The NOE transmits a Swap UDP message and swaps the IP address All client server services I O Scanner Global Data Messaging FTP SNMP and HTTP continue to run after the switchover from the old to the new Primary NOE Note Failure of an NOE module is not a condition for the primary system to leave the primary state 100 Configuring a Modicon Quantum Hot Standby with Unity System Hot Standby and The NOE 771 family provides different Ethernet services Some services are NOE Module enabled or disabled in a Modicon Quantum Hot Standby with Unity system The Functionality following table shows which services are enabled and disabled Service NOE 771 x1 I O Scanning Enabled Global Data Enabled Modbus Messaging Enabled FTP TFTP Enabled SNMP Enabled HTTP Server Enabled DHCP Disabled Note Only the 140 NOE 771 01 or 140 NOE 771 11 TCP IP Ethernet Modules support a Modicon Quantum Hot Standby with Unity V2 0 system 101 Configuring a Modicon Quantum Hot Standby with Unity System NOE Operating Modes and Modicon Quantum Hot Standby with Unity The NOE Modes The NOE modes are e Primary Mode The Hot Standby state is primary and all client server services are active e Secondary Mode The Hot Standby state is standby and all server services are active except DHCP e Standalone Mode Occurs when NO
17. HSBY BOOL 1 Hot Standby configuration PRY BOOL 1 This PLC is the primary PLC SBY BOOL 1 This PLC is the standby PLC FR_REV1 INT Content of first reverse transfer register SW62 Output only if HSBY is 1 FR_REV2 INT Content of second reverse transfer register Sw63 Output only if HSBy is 1 183 Using Modicon Quantum Hot Standby with Unity HSBY EFBs 184 Appendices Appendices for Quantum Hot Standby Planning and Installation Guide At a Glance The appendices for the Quantum Hot Standby Planning and Installation Guide are included here What s in this The appendix contains the following chapters ix Appendix Chapter Chapter Name Page A Modicon Quantum Hot Standby with Unity Additional Information 187 185 Appendices 186 Modicon Quantum Hot Standby with Unity Additional Information A Introduction Overview This chapter describes the necessary cables design specifications error codes What s in this This chapter contains the following topics 2 Chapter Topic Page Fiber Optic Cable 188 140 CPU 671 60 Specifications for Modicon Quantum Hot Standby with Unity 189 CRP Remote I O Head Processor Error Patterns 191 TextIDs 193 187 Additional Information Fiber Optic Cable Schneider Recommendations Electric i z 1 Use up to 2 km of 62 5 125 um graded index duplex multi
18. Action Result Copro Links 1 Standby RIO Head sends a Confirm whether Primary RIO request to the Primary RIO 1 Head failed or Head 2 link failed 2 Standby requests that the Main Main CPU passes this request to Copro either as a CPU monitor the Copro link 1 monitor RIO request 2 Copro link request To complete the process the Standby determines If Then Copro link is down and the Standby assumes control Primary is down Copro link is up Standby Copro sends a message to the Primary Copro and 1 Primary Copro passes this request to the Primary CPU 2 Primary checks the Primary RIO link Understanding Depending on the status the Primary RIO Head continues either to operate as the Communication Primary or goes offline Status tothe If communication Then Action Drops to drops is Healthy RIO link failure must 1 The station continues to operate as the be on Standby side Primary 2 Standby RIO Head shows the link error pattern on the LEDs Not healthy RIO link failure is on Primary side 1 The Primary RIO Head displays a link error 2 Standby assumes control 134 Maintaining a Modicon Quantum Hot Standby with Unity System Checking for Identical Application Programs Checksum Important Please note Information Fact Result A Hot Standby system requires that both This requirement prevents the Stand
19. Before doing any modifications and at the initial start up of your system do the following Step Action 1 From the menu select Tools Option 2 In the Options window select the General tab default 3 Select Automatic in the Upload Information Management area 4 Press OK to close the window 5 Save the program and download to the controller For major modifications to the application program on the Standby ensure the Standby is in offline mode Two benefits result from this action e Run process continues e Primary does NOT perform a switchover during modification of the Standby Note SWITCHOVER DURING MODIFICATION If the Standby is online during modifcations there is a possibilty of switchover occuring If a switchover occurs the Standby becomes Primary and the process may run with incomplete modifications 160 Logic Mismatch Performing Application Program Transfer Resetting Command Register System Bit SW60 3 When performing an application program transfer you want to avoid the possibility of having two different application programs running in the Primary and Standby Step Action 1 Perform Application program transfers after completing online modifications with Logic Mismatch When resetting the Command Register system bit SW60 3 to 0 you want to avoid the possibility of having two different application programs running in the
20. Identifiers cannot be keywords Used to indicate that a result of an operation is not a number NAN Not A Number Example calculating the square root of a negative number 204 Glossary Note The IEC 559 standard defines two classes of NAN quiet NAN QNAN and signaling NaN SNaN QNAN is a NAN with the most significant fraction bit set and a SNAN is a NAN with the most significant fraction bit clear Bit number 22 QNANS are allowed to propagate through most arithmetic operations without signaling an exception SNAN generally signal an invalid operation exception whenever they appear as operands in arithmetic operations See SW17 and S18 Network There are two meanings for Network e InLD A network is a set of interconnected graphic elements The scope of a network is local to the program organization unit section in which the network is located e With communication expert modules A network is a group of stations which communicate among one another The term network is also used to define a group of interconnected graphic elements This group forms then a part of a program which may be composed of a group of networks P Procedure Procedures are functions view technically The only difference to elementary functions is that procedures can take up more than one output and they support data type VAR_IN_OUT To the eye procedures are no different than elementary functions Procedures are a supplement to
21. NOE returns diagnostic code Bad IP configuration 107 Configuring a Modicon Quantum Hot Standby with Unity System Address Swap Times Description The following table details what the time for an Address swap comprises such as the time to close connections time to swap IP addresses or time to establish connections The following table shows the swap time for each of the Ethernet services Service Typical Swap Time Maximum Swap Time Swap IP Addresses 6ms 500 ms I O Scanning 1 initial cycle of I O Scanning 500 ms 1 initial cycle of I O scanning Global Data For swap times please see 500 ms 1 CPU scan the 840USE11600 Quantum NOE 771 xx Ethernet Modules User Guide Client Messaging 1 CPU scan 500 ms 1 CPU scan Server Messaging 1 CPU scan the time of the client reestablishment connection 500 ms the time of the client reestablishment connection FTP TFTP Server The time of the client reestablishment connection 500 ms the time of the client reestablishment connection SNMP 1 CPU scan 500 ms 1 CPU scan HTTP Server The time of the client reestablishment connection 500 ms the time of the client reestablishment connection 108 Configuring a Modicon Quantum Hot Standby with Unity System Network Effects of Modicon Quantum Hot Standby with Unity Solution Overview Browsers Re
22. Prog 1024kb Data 1600kb r TSX MRP C 002M SRAM PCMCIA Prog 2048kb Data 1856kb TSX MRP C 003M SRAM PCMCIA Prog 3072kb Data 2880kb TSX MRP C 007M SRAM PCMCIA Prog 7168kb Data 6976kb i TSX MRP C 768K SRAM PCMCIA Prog 768kb Data 576kb SRAM Data or Files SRAM Data or Files z TSX MRP F 002M SRAM PCMCIA Data or Files 2048kb TSX MRP F 004M SRAM PCMCIA Data or Files 4096kb TSX MRP F 008M SRAM PCMCIA Data or Files 8192kb 88 Configuring a Modicon Quantum Hot Standby with Unity System Step Action Add or replace the desired memory 89 Configuring a Modicon Quantum Hot Standby with Unity System Configuring the Modbus Plus Communication Type Configuring with Configuring the Modbus Plus communication type Unity Pro Step Action 1 If not opened open the Local Bus configuration editor 2 Go to the local bus in the Structural View of the Project Browser 3 Open the Local Bus editor either by double clicking on the Local Bus or by selecting the Local Bus and executing right click Open A graphical representation of the local bus appears Point to the Modbus Plus port No 3 e npe 4 A 1 A 1 A n n u n u Double click or right click on the Modbus Plus port The Submodule dialog appears The General tab is default
23. Using Initialized Data 120 Synchronizing Time of Day Clocks 121 112 Configuring a Modicon Quantum Hot Standby with Unity System Understanding the Non Transfer Area Transferring State RAM and Reverse Transfer Words Designating a Using the Hot Standby tab of the editor dialog you may designate a block of MW Non Transfer words as a Non Transfer area Area Step Action 1 Ensure that the Hot Standby tab is selected If you want to review the process for starting Unity Pro and opening the editor dialog please see Accessing the Base Configuration p 74 2 Enter the starting address in the system word field MW The field is located in the Non Transfer Area of the Hot Standby tab 3 Enter the number of contiguous registers in the Length field The field is located in the Non Transfer Area of the Hot Standby tab Non Transfer The designated registers will be ignored when state RAM values are transferred Area of State from the Primary controller to the Standby Placing registers in the Non Transfer RAM Area is one way to reduce scan time Note With the new hardware design of the Modicon Quantum Hot Standby with Unity 140 CPU 671 60s the scan time optimization provided by the Non Transfer area may be very low Transferring A pair of system words SW62 and SW63 are dedicated to transfer data from the Data to the Standby controller to the Primary Primary These system w
24. CRP firmware Release 1 14 or higher Note Who should use this document Anyone who uses a Hot Standby system or needs fault tolerant availability through redundancy in an automation system You should have knowledge of programmable logic controllers PLCs Familiarity with automation controls is expected You should possess a working knowledge of the Unity Pro software Familiarity with Concept ProWORX or Modsoft will help About the Book Validity Note Note Terminology This guide uses the following terminology e application program a project or logic program e controller a Unity Programmable Logic Controller PLC module which contains both 1 aCPU 2 a Copro e CPU Central Processing Unit a microprocessor in the controller which processes the application program e copro a microprocessor in the controller which communicates between two controllers e modify to edit or to change an application program e module any unit either a controller NOE RIO CRP CRA DDI AVO e scan program cycle Because Modicon Quantum Hot Standby with Unity systems deliver fault tolerant availability through redundancy use a Modicon Quantum Hot Standby with Unity system when downtime cannot be tolerated Redundancy means that two backplanes are configured identically A Modicon Quantum Hot Standby with Unity system must have identical configurations identical 140 CPU 671 60s which contain
25. Double Integer format coded on 32 bits The lower and upper limits are as follows 2 to the power of 31 to 2 to the power of 31 1 Example 2147483648 2147483647 16 FFFFFFFF DT is the abbreviation of Date and Time The DT type coded in BCD in 64 bit format contains the following information e The year coded in a 16 bit field the month coded in an 8 bit field the day coded in an 8 bit field the hour coded in a 8 bit field the minutes coded in an 8 bit field the seconds coded in an 8 bit field Note The 8 least significant bits are unused The DT type is entered as follows DT lt Year gt lt Month gt lt Day gt lt Hour gt lt Minutes gt lt Seconds gt This table shows the lower upper limits in each field Field Limits Comment Year 1990 2099 Year Month 01 12 The left 0 is always displayed but can be omitted at the time of entry 199 Glossary Field Limits Comment Day 01 31 For the months 01 03 05 07 08 1 0 12 01 30 For the months 04 06 09 11 01 29 For the month 02 leap years 01 28 For the month 02 non leap years Hour 00 23 The left 0 is always displayed but can be omitted at the time of entry Minute 00 59 The left 0 is always displayed but can be omitted at the time of entry Second 00 59 The left 0 is always displayed but can be omitted at the time of entry DWORD DWORD is the abbre
26. Hot Standby with Unity System Synchronizing Time of Day Clocks Setting the Time In a Modicon Quantum Hot Standby with Unity system the Primary and Standby of Day Clocks in controllers have their own Time of Day clocks which are not implicitly synchronized the Primary and If the clocks are not synchronized then at switchover the Time of Day would Standby change by the difference between the two clocks Non synchronization of the clocks Controllers could cause problems if you are controlling a time critical application 121 Configuring a Modicon Quantum Hot Standby with Unity System 122 Maintaining a Modicon Quantum Hot Standby with Unity System 6 Introduction Overview What s in this Chapter This chapter provides information about maintaining a Modicon Quantum Hot Standby with Unity system This chapter contains the following topics Topic Page Verifying the Health of a Modicon Quantum Hot Standby with Unity System 124 Detecting and Diagnosing Failures in a Modicon Quantum Hot Standby with 125 Unity System Detecting Primary Controller Copro and RIO Head Failures 127 Detecting Standby Controller Copro and RIO Head Failures 129 Detecting High Speed Data Link HDSL Failures 130 Detecting Remote I O RIO Link Failures 133 Checking for Identical Application Programs Checksum 135 Replacing a Faulty Module 136 Troubleshooting the Primary Controlle
27. IEC 61131 3 R REAL Real type is a coded type in 32 bits The ranges of possible values are illustrated in gray in the following diagram LE E i 7 E INF 3 402824e 38 1 1754944e 38 0 0 1 1754944e 38 3 402824e 38 When a calculation result is e between 1 175494e 38 and 1 175494e 38 it is considerd as a DEN e less than 3 402824e 38 the symbol INF for infinite is displayed 205 Glossary Real Literals Real Literals with Exponent e greater than 3 402824e 38 the symbol INF for infinite is displayed e undefined square root of a negative number the symbol NAN or NAN is displayed Note The IEC 559 standard defines two classes of NAN quiet NAN QNAN and signaling NaN SNaN QNAN is a NAN with the most significant fraction bit set anda SNAN is a NAN with the most significant fraction bit clear Bit number 22 ONANS are allowed to propagate through most arithmetic operations without signaling an exception SNAN generally signal an invalid operation exception whenever they appear as operands in arithmetic operations See SW17 and S18 Note when an operand is a DEN Denormalized number the result is not significant An literal real value is a number expressed in one or more decimals Example 12 0 0 0 0 456 3 14159 _26 An Literal decimal value can be expressed using standard scientific notation The representation is as follows mantissa exponential Example 1 34E 12
28. RAM 49 status registers 117 transfer 49 drops remote I O 63 E EFBs 148 171 ENTER buttons 23 28 error logs 125 error patterns 192 errors checksum 191 Com Act 137 138 191 detecting 127 hard 127 I O 46 191 interface 137 138 ESC buttons 23 28 events 83 EXEC upgrades 115 142 F failures controllers 138 detecting 127 128 dual cables 137 138 fiber links 62 138 high speed data links HSDL 130 RIO cables 137 138 types 126 fiber optic cables 62 G Global Data 149 green indicators 26 212 Index H hard errors 127 health messages 124 125 130 healthy communications 134 hubs 62 I O errors 46 I O maps 148 I O transactions 131 identical programs 146 indicators blinking 26 137 138 green 26 LED 25 red 26 status 137 138 steady 137 steady off 26 steady on 26 interface errors 137 138 Invalidate Keypad 92 K key switches 22 28 keypads 22 23 92 L LCDs backlights 24 communications screens 33 default screens 29 displays 21 25 27 LCD settings screens 37 PLC operations screens 30 system info screens 36 LED indicators 25 lens covers 21 limits transfer size 165 located variables 48 locked key switch 22 logic mismatches 118 146 150 logs errors 125 M MAST scans 51 menus communications 33 default 29 LCD display screens 27 LCD settings 37 PLC operations 30 system 36 messages heal
29. RAM Description 768 kbytes memory for on board program and unlocated data extensible to 7 168 Mb by PCMCIA 128 kbytes max memory for configuration 64 kwords memory for located data state RAM 8 192 kbytes PCMCIA extension for data storage Discrete bits 64 k any combination Registers words 64 k max 189 Additional Information Remote I O Max I O words drop 64 in 64 out Max number of remote drops 31 This information can be a mix of discrete or register I O For each word of configured I O one of the I O words must be subtracted from the total available Battery and Glock Battery type 3 V Lithium Service life 1200 mAh Shelf life 10 years with 0 5 loss of capacity year Battery load current power off typical 14 uA max 420 uA TOD clock 8 0 s day 0 60 C Diagnostic Power up RAM RAM address Executive Checksum User Logic Check Processor Run Time RAM RAM address Executive Checksum User Logic Check 190 Additional Information CRP Remote I O Head Processor Error Patterns Error Patterns The following table displays both e number of times the Com Act indicator blinks for each type of error e possible codes for each type of blink 191 Additional Information All codes are in hex
30. Standby switch to Primary 8 Perform application program transfer I If controller A is the Primary controller and its Modbus port has an address of 1 then the default addresses for the comparable port on controller B the Standby is 129 which is 1 plus the offset of 128 If controller B becomes the Primary controller as the result of a switchover its Modbus port assumes the address of 1 and the comparable port on controller A assumes the address of 129 95 Configuring a Modicon Quantum Hot Standby with Unity System No Swap Modbus Addresses at Switchover Important Information Handling Modbus Plus Addresses at Switchover If controller A is the Primary controller and its Modbus port 1 address is 1 then that port address remains at 1 after the switchover occurs Likewise if controller B becomes the Primary controller as a result of a switchover its Modbus port 1 address is remains at 1 Note Important Information 1 If you change the options the port addresses are not affected until a switchover occurs 2 If NOM modules are used in the configuration the offset of the Modbus address is 32 following the Modbus Plus address switchover In a Modicon Quantum Hot Standby with Unity system the Modbus Plus port addresses on the Standby controller are offset 32 from the comparable ports on the Primary controller Modbus Plus address swap behavior at switchover D
31. and set up these functions in your program in order to carry out your application You can also develop other functions using the SDKC development kit EFB Is the abbreviation for Elementary Function Block This is a block which is used in a program and which performs a predefined software function EFBs have internal statuses and parameters Even where the inputs are identical the output values may be different For example a counter has an output which indicates that the preselection value has been reached This output is set to 1 when the current value is equal to the preselection value Elementary see EF Function EN EN means ENable this is an optional block input When EN is activated an ENO output is automatically drafted If EN 0 the block is not activated its internal program is not executed and ENO ist set to 0 If EN 1 the internal program of the block is executed and ENO is set to 1 by the system If an error occurs ENO is set to 0 ENO ENO means Error NOtification this is the output associated to the optional input EN If ENO is set to 0 caused by EN 0 or in case of an execution error e the outputs of function blocks remain in the status they were in for the last correct executed scanning cycle and e the output s of functions and procedures are set to 0 F FBD FBD is the abbreviation of Function Block Diagram 201 Glossary FBD is a graphic programming language that operates as a logic
32. bits in the Command Register do the following Step Action 1 Open file 1 Connect to the Primary Ensure the controller order of the Primary is A or B AJOJN Access e Command Register system bit SW60 1 If the connected controller order is A e Command Register system bit SW60 2 If the connected controller order is B Set bit to 0 Note Ensure that the Standby switched to Primary Open file 2 Connect to the new Primary controller Access the Command Register system bit used in Step 4 olo NIO Set bit to 1 Note Ensure Standby controller is now online 10 Ensure both Primary and Standby controllers are in Run Primary and Run Standby mode 158 Logic Mismatch Application Program Transfer Method and Logic Mismatch General Application Program Transfer Using Front Panel Keypad Application Program Transfer Using Command Register System Bit SW60 5 Application Program Transfer can be performed using one of two methods e Hot Standby submenu on the front panel keypad e Command Register system bit SW60 5 To transfer an application program logic program or project to either the Primary or Standby controller using the front panel keypad do the following gt Step Action 1 Access the front panel keypad of any controller Primary or Standby Go to PLC Operations menu Go to Hot Standby submenu AJ
33. bus appears in the configuration editor 2 Select the Modicon Quantum Hot Standby with Unity 140 CPU 671 60 module and right click The context menu appears Select Open Module The editor appears The Summary tab is the default 72 Configuring a Modicon Quantum Hot Standby with Unity System Unity Pro Hot Standby Editor Dialog The editor with the Hot Standby tab selected 1 2 140 CPU 671 60 P266 CPU Hot Standby 1Mb Program PCMCIA Ethernet HSBY Fiber optic USB MB MB Biel E E Over F Sum Conti MB Modb F Anima 4k Hot St F 1 0 objects Run Mode Invalidate Keypad Controller A Online v Yes Controller B Online v Standby On Logic Mismatch Swap Address At Switchoverp Offline M Modbus Port 1 o M Modbus Port 2 Online W Modbus Port 3 State RAM Non Transfer Area Start MW 0 Length 0 73 Configuring a Modicon Quantum Hot Standby with Unity System Accessing the Base Configuration Accessing with Unity Pro After starting Unity Pro go to the Local Bus in the Structural View of the Project Browser Step Action 1 Open the Local Bus configuration editor either by double clicking on the Local Bus or by selecting the Local Bus and executin
34. cities eid peer EEA A ye ia he E a E ded ate ee we 99 Overview of Modicon Quantum Hot Standby with Unity Solution for NOEs 100 NOE Operating Modes and Modicon Quantum Hot Standby with Unity 102 IP Address Assignment 0 0 00 ee eee tenes 106 Address Swap TimeS 1 2 0 0 cece teeta 108 5 3 Chapter 6 Part Ill Chapter 7 Chapter 8 Network Effects of Modicon Quantum Hot Standby with Unity Solution 109 Configuring Registers with Unity Pro 1 0 2 2 eee ee 112 Ata Glacen erreian ees iow E Oe ee ee 112 Understanding the Non Transfer Area Transferring State RAM and Reverse Transfer Words dp004 nee a Oe idiad A eee pbs 4 hos 113 Understanding the Unity Command Register 00200000e 114 Understanding the Unity Status Register 0 0 0 eee eee eae 117 Transferring User Data 1 ee tte 119 Using Initialized Data 0 tee 120 Synchronizing Time of Day ClockS 0 000 c eects 121 Maintaining a Modicon Quantum Hot Standby with Unity System Seki seeh eee e ee Sees eee eee ee he aa ee 123 Introduction sv fone ek he Peed heed Pe a ae ee Me Ae a ee A 123 Verifying the Health of a Modicon Quantum Hot Standby with Unity System 124 Detecting and Diagnosing Failures in a Modicon Quantum Hot Standby with Unity Syster aaa are hata hota Shits a a eat acs oh adopts Reich adnate ae the 125 Detecting Primary Controller Copro and RIO Head Failures 127 Dete
35. eg 57 Setting Up the Modicon Quantum Hot Standby with Unity System 58 Mapping the Backplane Extension 0 00 e eee eee eee eee 60 Connecting Two Modicon Quantum Hot Standby with Unity HE CPU 671 60s 62 Connecting the Remote I O 1 0 0 ccc tte ee 63 Testing the Modicon Quantum Hot Standby with Unity System 66 Configuring a Modicon Quantum Hot Standby with Unity SV SLI cose oes ages eae cana acetate hates de teks ar RAN a aaa tad Seer s 69 InthodUGHION sade sect gue ey baste se hea ee ates SG aye ante eee ie 69 Configuring a System with the Unity Pro Tabs and Dialogs 70 Atsa GlanGe secs der tata aie pena ads ab yee ete eet 70 Introducing Unity Pro 1 ete 71 Accessing the Base Configuration sssaaa cece eee 74 Using the Summary Tab 0 000 c ete tte eee 75 Using the Overview Tab 0 c eet ttt eee 76 Using the Configuration Tab 0 0 cece eee 77 Using the Modbus Port Tab 000 cece eee 80 Using the Animation Tab and PLC Screen Dialogs 2 0000 82 Using the Hot Standby Tab 1 0 0 0 eck eta 86 Configuring the PCMCIA Cards 0 0 ccc tees 88 Configuring the Modbus Plus Communication Type 200005 90 Setting the Invalidate Keypad Option 0 0 0 cece ee eee 92 Swapping Network Addresses at Switchover 0000 eee eeee 94 Configuring a NOE with Unity Pro 1 ee 99 Aba Glance
36. mismatch in firmware Normally when a mismatch exists performing a switchover would not be possible because the Standby controller would not be allowed to go online However to allow an EXEC Upgrade without stopping the application overriding is possible by setting the Command Register system bit SW60 4 Details of the Modicon Quantum Hot Standby with Unity command register can be found in Understanding the Unity Command Register p 114 Note Enabling EXEC upgrade without stopping the application overrides the process of checking whether the Primary and Standby are configured identically Disable the upgrade without stopping bit as soon as the EXEC upgrade is finished Note IMPORTANT INFORMATION EXEC upgrade is possible only with compatible firmware 142 Enabling EXEC Upgrade Executing the EXEC Upgrade Procedure General Using Modbus RTU Important Perform an EXEC upgrade using the installed OSLoader tool Use one of two communication methods available in the OSLoader e Modbus RTU e Modbus Plus Follow these steps Step Action 1 Connect to the Primary Access the Command Register system bit SW60 4 set bit to 1 Disconnect the fiber optic cable on both controllers Open the OSLoader tool Select the Modbus communication option Stop the Standby NN QO oa AJOIN Connect to the Standby using Modbus Note Use the Standby s
37. not including in the upload information e Exclude by selecting Tools Project Settings Build tabs default In the Upload Information area select without e Not including requires downloading application program When a mismatch exists a switchover is not possible and the Standby controller would NOT go online However there are situations when you may want to allow a mismatch between the application programs To enable this condition use the Modicon Quantum Hot Standby with Unity Logic Mismatch feature Note Switchover can NOT occur while the Standby controller is offline Logic Mismatch is a Modicon Quantum Hot Standby with Unity feature that allows a mismatch between the application programs of the Primary and Standby controllers Use the Logic Mismatch feature to modify an application program without stopping the process Note Build Project vs Rebuild All Project 1 Use the Build Project function to perform a logic mismatch with Unity Pro Schneider Electric recommends do not use Rebuild All Project to create a logic mismatch because the Rebuild All Project function creates a completely new project even if nothing has been changed in the application 146 Logic Mismatch Causing a Mismatch Allowing a Mismatch Creating a Mismatch Note CHANGING FROM LEGACY Legacy Hot Standby systems reserved areas of the State RAM for user data which was transferred from
38. terminating F adapter Splitter MA 0186 100 Tap MA 0185 100 Trunk Terminator 52 0422 000 64 Installation and Cabling Connecting over Long Distances If you intend to place the units more than 3 meters apart you have to consider the effect on the RIO network and any Modbus Plus network The controllers are linked to the RIO network by coaxial cable The longer the distance between the controllers the higher the grade of trunk cable required to maintain signal integrity Refer to the Remote I O Cable System Planning and Installation Guide 890 USE 101 00 for details regarding cable grades distances and signal integrity If no coaxial cable will be sufficient to maintain signal integrity throughout the RIO network fiber optic repeaters may be used to boost the signal Refer to the Modbus Plus Network Planning and Installation Guide UNY USE 10410 V10E for details on extending a Modbus Plus network 65 Installation and Cabling Testing the Modicon Quantum Hot Standby with Unity System Testing Methods First Time Hot Standby Start up and Application Program Transfer Follow these steps to conduct tests to observe e Hot Standby start up e automatic Application Program Transfer e switchover of control from Primary to Standby These tests are not necessary but helpful If your backplanes are horizontally parallel and within 1 meter 3 feet apart the transfer process is easier to observe
39. the appropriate values All values depend on Hot Standby configuration 78 Configuring a Modicon Quantum Hot Standby with Unity System Using the State RAM Viewer The State RAM Viewer dialog gt State Ram Viewer o 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 0 100 200 300 400 500 600 700 800 900 1000 1100 v 4 gt Modules Variables Language Legend r Address Information EEE Modules Address M 0 Go To Ml Language Module Address es Variables r Memory Area M 0x O l 1x O IW 3x MW 4x Each cell in the grid represents an address location and displays the entity stored in that location The contents of the grid may be changed by selecting options in either of two filters 1 Memory used grid options Select one or all of the three options using the check box and one to three bar graphs appear Modules Indicates the topological address used in the modules Address appears as a bar graph in the grid Language Indicates the topological address used in the program Address appears as a bar graph in the grid Variables Indicates the topological address used in the variables Address appears as a bar graph 2 Me
40. variables sections DFB types etc 203 Glossary L LD LD is the abbreviation of Ladder Diagram LD is a programming language representing the instructions to be carried out in the form of graphic diagrams very close to a schematic electrical diagram contacts coils etc Located A located variable is a variable for which it is possible to know its position in the PLC variables memory For example the variable Water_pressure is associated withmw102 Water_pressure is Said to be localized M Multiple Token Operating mode of an SFC In multitoken mode the SFC may possess several active steps at the same time Naming conventions Identifier NAN An identifier is a sequence of letters numbers and underlines beginning with a letter or underline e g name of a function block type an instance a variable or a section Letters from national character sets e g 6 U 6 can be used except in project and DFB names Underlines are significant in identifiers e g A_BCD and AB_CD are interpreted as different identifiers Multiple leading underlines and consecutive underlines are invalid Identifiers cannot contain spaces Not case sensitive e g ABCD and abcd are interpreted as the same identifier According to IEC 61131 3 leading digits are not allowed in identifiers Nevertheless you can use them if you activate in dialog Tools Project settings in tab Language extensions the ceck box Leading digits
41. 0 coaxial splitter has to be installed between the RIO head processors and the RIO network e The remote drops have to be connected to the trunk cable via an MA 0185 100 tap and a drop cable e The last tap on a trunk cable has to be terminated with a 52 0422 000 trunk terminator Remote drops have not be connected directly to the trunk cable e An optional 60 0545 000 Ground Block at the head will provide earth ground connection when the cable and RIO processor are disconnected Ground blocks may also be used at other ground points along the trunk cable as required Refer to the Remote I O Cable System Planning and Installation Guide 890 USE 101 00 for details Note CABLING REQUIREMENTS e f you are using a Modicon Quantum Hot Standby with Unity system for data logging the RIO heads have to be configured and connected with coaxial cable and you have to configure one 1 or more RIO drops 63 Installation and Cabling The following diagram shows the hardware required for the Remote I O cabling oON OA FWD __ gt gt t Io ns be le Primary controller Standby controller Modicon Quantum RIO head Modicon Quantum RIO drop Coaxial cable components shown with dashed lines are not mandatory Self
42. 0x8000 e While the NOE is in the process of performing the transaction anew MSTR IEC function block may become active e The output states of the scanned I Os will follow the state defined in the last value option configured in the I O scanning table of the NOE module in Unity Pro software These two states are either 1 set to 0 2 Hold last With the above considerations Schneider Electric recommends using switchover with Ethernet I O scanning for less critical applications 110 Configuring a Modicon Quantum Hot Standby with Unity System Global Data Publish Subscribe Service FTP TFTP Server The Hot Standby NOE is one station within a distribution group Distribution groups exchange application variables Exchanging application variables allows the system to coordinate all the stations in the distribution group Every station publishes local application variable in a distribution group for all other stations and can subscribe to remote application variables independent of the location of the producer The communication port has only one multicast address In this network service the Modicon Quantum Hot Standby with Unity controllers are viewed like only one station The Primary NOE publishes the Hot Standby application variables and receives the subscription variables The Secondary NOE global data service is in a stopped state When the Hot Standby swap occurs the Primary NOE stops the Global Data
43. 35010533_00 abrand of Schneider Electric Modicon Quantum Hot Standby with Unity Pro User Manual eng June 2005 Telemecanique Table of Contents Part Chapter 1 Chapter 2 Chapter 3 Safety Information 2543 4es0se Geers Vee ee eRe 7 About the Book 2 vesee sees ewes saa eee wees eae 9 Introducing the Modicon Quantum Hot Standby with Unity System a rei eae Ce EER R ee ad alee HE 13 Ata GlanGe s ntin a boii era kev iets ee enide eto iektales ke 13 Modicon Quantum Hot Standby with Unity Overview 15 Introduction hacia felted get eee le aug th dada chin dept ln er edd ang ten 15 Overview of the Modicon Quantum Hot Standby with Unity System 16 Modicon Quantum Hot Standby with Unity 140 CPU 671 60 Module Overview 18 Modicon Quantum Hot Standby with Unity System Overview 19 Modicon Quantum Hot Standby with Unity 140 CPU 671 60 Components 21 Operating the Modicon Quantum Hot Standby with Unity 140 CPU 671 60 Keypads vin ac ive hei Sete ere e EO ieee Pee bes eon ees 23 Using the Modicon Quantum Hot Standby with Unity 140 CPU 671 60 LED Indicators cic aaa a aetoene a p Cota yee Mea he a ee 25 Using the Modicon Quantum Hot Standby with Unity 140 CPU 671 60 LCD Display Screens iton n E E tee teens 27 Modicon Quantum Hot Standby with Unity Compatibility Differences and Restrictions 00000ce eens 39 Introduction ni a ek eae pA pee ae Gees ene eee 39 Compatibility wit
44. 48 setup methods Hot Standby System 58 SFC sections 151 specifications 189 splitters coaxial 63 standalones 125 127 128 Standby controllers time of day clocks 121 state RAM 48 49 71 79 147 states Hot Standby 31 static data memory layout 147 status registers 117 steady indicators 29 steady off indicators 26 steady on indicators 26 submenus default screen 29 Hot Standby 31 Init 31 LCD contrast 37 LCD display screens 27 LCD Light 37 Modbus Plus 34 PLC operations screens 30 serial port 35 Star 31 Stop 31 System Info 36 TCP IP Ethernet 34 214 Index switches 62 switchovers 94 116 125 USB 45 system bits 41 114 118 system information 84 system words 41 114 118 T tabs Animation 82 Configuration 77 Hot Standby 86 Information 84 Modbus Port 80 Overview 76 Realtime clock 83 Summary 75 Task 82 take control commands 127 TCP IP 94 tests confidence 124 Hot Standby systems 66 of the Copro 124 run time 124 start up 66 startup 124 switchover 68 textids 193 time of day clocks 121 timer events 46 times 83 address swaps 108 transfer 50 164 transferring programs 164 transfer size limits 165 trunk terminators 63 U unlocated variables 48 71 115 118 unlocked key switch 22 up buttons 23 28 updating offline 120 Primarys 164 Standbys 164 upgrades 142 Upload Information Management 160 user data 14
45. 6 Offline keypad switch 13007 Offline Command register request TextIDs switching from Standby to Offline TextID Warning message 13008 System halt 13009 Remote IO failure 13010 ETH device failure 13011 ETH communication problem 13012 Stop PLC command 13013 Offline keypad switch 13014 Offline Command register request TextIDs switching from Standby to Primary TextID Warning message 13015 Control command over ETH 13016 Control command over RIO TextIDs switching from Offline to Primary Standby TextID Warning message 13017 Switch from Offline to Primary 13018 Switch from Offline to Standby BY 193 Additional Information 194 Glossary l IW KW M MW Q QW According to the IEC standard 1 indicates a discrete input type language object According to the IEC standard Iw indicates an analog input type language object According to the IEC standard Kw indicates a constant word type language object According to the IEC standard m indicates a memory bit type language object According to the IEC standard mw indicates a memory word type language object According to the IEC standard Q indicates a discrete output type language object According to the IEC standard sQw indicates an analog output type language object A ADDR_TYPE ANL_IN This predefined type is used as output for ADDR function This
46. 7 148 V values initial 120 variables 149 declared 149 located 48 148 redeclared 149 section 149 transition 149 unlocated 48 71 115 118 148 W warm starts 83 warnings Configuration Hazard 148 I O Map Hazard 148 Immediate Control of Process 152 156 Switchover Hazard 151 215 Index 216
47. Command Register Set the system bit SW60 0 to 1 Selecting the system bit SW60 0 must be performed online in the Primary controller Note By setting the Invalidate Keypad option the Run Stop PLC control option on the PLC Operation menu is NOT disabled 92 Configuring a Modicon Quantum Hot Standby with Unity System Disabling Options Two Hot Standby options controls are disabled using the front panel keypad e Changing the HSBY mode Run Offline e Application program transfer to from Standby Note CHANGING FROM LEGACY In the legacy Quantum Hot Standby system setting command register bit 16 affects both the mode offline or run of controllers A and B and affects the state of bit 14 and bit 15 e Bit 16 set to 0 e disables overrides Command Register bit 14 and bit 15 state e enables key switch state e Bit 16 set to 1 e enables Command Register bit 14 and bit 15 state e disables key switch state In Unity e the state condition of system bit SW60 0 ONLY disables enables the Hot Standby submenu option in the front panel keypad e setting system bit SW60 0 does NOT affect the state of system bits SW60 1 and SW60 2 e regardless of the setting for system bit SW60 0 system bits SW60 1 and SWEO0 2 control the mode offline or run of controllers A and B See Setting the Bits in the Command Register p 114 93 Configuring a Modicon Quantum Hot Standby with Unity
48. E is in a nonredundant system or if the HE CPU module is not present or is not healthy e Offline Mode CPU is stopped CPU module is in Offline mode The Modicon Quantum Hot Standby with Unity and the NOE operating modes are synchronized by the conditions described in the following table HE CPU Module Status HSBY State NOE Operating Mode Present and Healthy Primary Primary Present and Healthy Standby Secondary Present and Healthy Offline Offline Present and Healthy Unassigned Standalone Not present or unhealthy N A Standalone Any one of four events will affect the NOE operating mode These four events occur when the NOE is powered up when an NOE executes a Hot Standby switchover when an NOE goes to offline mode or when a new application is downloaded to the NOE 102 Configuring a Modicon Quantum Hot Standby with Unity System Power Up and IP An NOE obtains its IP Address assignment at power up as follows Address If the HSBY state is Then the IP Address assigned is Assignment Unassigned Configured IP Address Primary Configured IP Address Secondary Configured IP Address 1 Unassigned to Offline See the Offline Mode at Power up Sequence table following If two NOEs power up simultaneously a resolution algorithm determines the Primary NOE and after determining the Primary NOE the resolution algorithm assigns the configured IP Address
49. HSBY_RD_ Instance HSBY_RD EN ENO HSBY HSBY_ConfigurationFound CON SJ InvalidateKeypad O INV_KEY PCA_RUN ie PLC_A_Running Gy Sen PLC_B_Running PCB_RUN SBY_OFF G2 StandbyOff N Ca EXC_UPD ExecUpdate S A SwapAddressModbusPort1 D SWP_MB1 SWP_MB2 SWP_MB3 7 ad Representation CAL HSBY_RD_Instance HSBY gt HSBY_ConfigurationFound INV_KEY gt InvalidateKeypad PCA_RUN gt PLC_A_ Running PCB_RUN gt PLC_B Running SWP_MB1 gt SwapAddressModbusPort1 EXC_UPD gt ExecUpdate SBY_OFF gt StandbyOff Representation HSBY_RD_Instance HSBY gt HSBY_ConfigurationFound INV_KEY gt InvalidateKeypad PCA_RUN gt PLC_A_ Running PCB_RUN gt PLC_B_ Running EXC_UPD gt ExecUpdate SBY_OFF gt StandbyOff SWP_MB1 gt SwapAddressModbusPort1 173 Using Modicon Quantum Hot Standby with Unity HSBY EFBs Parameter Description of the output parameters description Parameter Data type Meaning HSBY BOOL 1 Hot Standby configuration found INV_KEY BOOL 1 The submenu for the Hot Standby PLC button is disabled PCA_RUN BOOL 1 The PLC with the Hot Standby CPU 1 function is A on local rack 2 Command Register is selected RUN 0 The PLC with the Hot Standby CPU 1 function is A on local rack 2 Command Register is selected OFFLINE PCB_RUN BOOL 1 The PLC with the Hot Sta
50. IO Head s status displayed by the RIO Head s LEDs Controller RIO Head Status Failure Type Description Status Stop All LEDS off except Controller An Interface error occurred READY on or READY on and Com Act blinks once a second Offline READY on and Com _ Fiber Optic A Com Act error occurred Act stops blinking connection between both controllers Stop Com Act displays error RIO Head After you have replaced the pattern module and cycled power to ensure that the controllers have identical application programs you must perform an application program update Stop READY on and Com RIO Cable Failure at Ina dual cable system the RIO Act blinks four times Standby end Head gives no indication if only one cable has failed Offline Com Act stops blinking Fiber Link failures e from Standby Transmit to Primary Receive e from Primary Transmit to Standby Receive 138 Understanding the Modicon Quantum Hot Standby with Unity System Special Features At a Glance Purpose What s in this Part This part describes the special features of a Modicon Quantum Hot Standby with Unity system e enabling an EXEC upgrade e handling logic mismatch e transferring application programs This part contains the following chapters Chapter Chapter Name Page 7 Enabling EXEC Upgrade with Unity Pro 141 8 Handling Logic Mismatch with Unity Pro 145 9 Transferring an Application Pro
51. Logic Mismatch p 155 94 Configuring a Modicon Quantum Hot Standby with Unity System Swap Modbus Addresses at Switchover Using the Communication menu in the Front Panel Keypad Note If the Modbus address is changed in the Primary using the front panel keypad ensure that application program transfer is made to enable the corresponding Modbus switchover in the Standby Note CHANGING FROM LEGACY In a Modicon Quantum Hot Standby with Unity system only one port is available for Modbus By default address swap at switchover is maintained between the Primary and Standby Modbus ports This default condition can be changed using the following two methods e Using Hot Standby menu in the Unity Pro editor This choice requires the application program to be downloaded e Using the Command Register system bit SW60 8 This choice MUST be performed online in the Primary Selecting deselecting address swap at Switchover Using Hot Standby Menu in Editor Using the Command Register system bit SWE0 8 1 Open Hot Standby menu in Unity Pro 1 Connect to Primary 2 Go to Swap Address at Switchover area 2 Access the Command Register System 3 Deselect Modbus Port 1 bit SW60 8 4 Verify modifications 3 Set bit to 1 5 Download application program to Default is 0 controller See Offline Modification of an Application Program and Logic Mismatch p 155 6 Perform switchover Ensure
52. MB Indicates Modbus Plus activity mb No activity Modbus 232 Serial port activity for RS 232 485 Serial port activity for RS 485 PCM Indicates the card in slot 1 is being accessed The status displayed indicates the health of the battery e Steady Battery is OK e No message Batery is low Blinks when the card in slot 2 is being accessed The status displayed indicates the health of the battery e Steady Battery is OK e No message Batery is low 29 Overview Modicon Quantum Hot Standby with Unity Using the PLC Structure PLC Operations menu and submenus Operations Menus and Quantum Submenus PLC Operations gt _ PLC Operations Press lt ENTER gt to Start PLC gt confirm Start gt _ PLC Operations Press lt ENTER gt to Stop PLC gt confirm Stop gt PLC Operations Press lt ENTER gt to Init PLC gt confirm Init gt _ PLC Operations Hot Standby Hot Standby gt State State Hot Standby Mode Mode Hot Standby Order 000000 Hot Standby Press lt ENTER gt to Transfer gt confirm Transfer gt Hot Standby Hot Standby Diag gt diag halt Hot Standby diag rio fails Hot Standby diag hsby fails Hot Standby diag stop Hot Standby diag off keypad
53. Modbus address Download the OS to the Standby After completing the OS download perform application program transfer to the Standby 10 Reconnect the fiber optic cables 11 Put in RUN mode Note Ensure Primary and Standby are in RUN Primary and RUN Standby mode Perform a switchover Note Ensure Standby becomes Primary 13 Repeat Steps 4 through 9 on the new Standby 14 Connect to the new Primary 15 Access Command Register system bit SW60 4 set bit to 0 If you upgrade using Modbus Plus only address 1 is allowed for downloading Otherwise there is no communication Ensure that no device in the Modbus Plus network is using the address 1 See Handling Modbus Plus Addresses at Switchover p 96 143 Enabling EXEC Upgrade Using Modbus Plus Compatibility Issues Follow these steps Step Action 1 Connect to the Primary 2 Access the Command Register system bit SW60 4 set bit to 1 3 Note Before stopping the Standby note the Modbus Plus address Stop the Standby 4 Disconnect the fiber optic cable from both controllers Note Primary operates without a Standby Switch off power and switch on power to the Standby If not set to 1 change the Modbus Plus address of the Standby to 1 Open the OSLoader tool N oJ A Connect the Standby using Modbus Plus Note Use the Standby s Modbus Plus add
54. NY_ARRAY_ANY_BIT ANY_ARRAY_DWORD ANY_ARRAY_WORD ANY_ARRAY_BYTE ANY_ARRAY_BOOL ANY_ARRAY_ANY_STRING ANY_ARRAY_STRING ANY_ARRAY_ANY_DATE ANY_ARRAY_DATE_AND_TIME ANY_ARRAY_DATE NY_ARRAY_TIME_OF_DAY ANY_ARRAY_EBOOL ANY_ARRAY_ANY_DDT ANY_STRUCTURE ANY_DDT ANY_IODDT ANY_FFB ANY_EFB ANY_DFB 196 Glossary ARRAY An ARRAY is a table of elements of the same type The syntax is as follows ARRAY lt terminals gt OF lt Type gt Example ARRAY 1 2 OF BOOL is a one dimensional table made up of two BOOL type elements ARRAY 1 10 1 20 OF INT isa two dimensional table made up of 10x20 INT type elements B Base 10 literals Base 16 Literals Base 2 Literals Base 8 Literals BCD A literal value in base 10 is used to represent a decimal integer value This value can be preceded by the signs and If the character _ is employed in this literal value it is not significant Example 12 0 123_456 986 An literal value in base 16 is used to represent an integer in hexadecimal The base is determined by the number 16 and the sign The signs and are not allowed For greater clarity when reading you can use the sign _ between bits Example 16 F_F or 16 FF in decimal 255 16 F_F or 16 FF in decimal 224 A literal value in base 2 is used to represent a binary integer The base is determined by the number 2 and the sign The signs and are not allowed For grea
55. OJN Go to Hot Standby transfer and press ENTER to confirm the transfer Note Ensure transfer to Standby occurs To transfer an application program logic program or project to either the Primary or Standby controller using Command Register system bit SW60 5 do the following Step Action 1 Connect to the Primary controller 2 Access Command Register system bit SW60 5 3 Set bit to 1 Note The process of setting the bit toggles the bit from 0 to 1 and back to 0 159 Logic Mismatch Recommendations for Using Logic Mismatch General Upload Information Management Feature General Using the Upload Information Management Feature Handling Online Modifications to the Standby When using the Logic Mismatch feature Schneider Electric recommends noting that the following are affected e Upload Information Management e Online modifications to the Standby e Application Program Transfer e Setting the Command Register system bit SW60 3 During online modifications your system detects that the application program information in the controller differs from the application program information in the computer Because this information will be used later when an upload is performed the system requires you to update this information and constantly presents a confirmation dialog To avoid constant display of the dialog use the Upload Information Management feature
56. Port1 HSBY gt HSBY_ConfigurationFound Representation Representation in ST HSBY_WR Instance INV_KEY InvalidateKeypad PCA_RUN PLC_A Running PCB_RUN PLC_B Running SWP_MB1 SwapAddressModbusPort1 HSBY gt HSBY_ConfigurationFound 179 Using Modicon Quantum Hot Standby with Unity HSBY EFBs Parameter Description of the input parameters description Parameter Data type Meaning INV_KEY BOOL In the submenu for the Hot Standby PLC button 1 Changes are disabled 0 Changes are allowed PCA_RUN BOOL 1 gt 0 The Hot Standby CPU with A function on the local rack is forced into OFFLINE mode 0 gt 1 The Hot Standby CPU with A function is forced into RUN mode if its own button mode is in RUN mode PCB_RUN BOOL 1 gt 0 The Hot Standby CPU with B function on the local rack is forced into OFFLINE mode 0 gt 1 The Hot Standby CPU with the B function is forced into RUN mode if its own button mode is in RUN mode SWP MB1 BOOL 0 and a switchover happened The Modbus address on port 1 of the NEW primary PLC changes new primary PLC address old primary address e new standby PLC address new primary address 128 1 and a switchover happened The Modbus address on Port 1 of the PLC don t changes new primary PLC address old primary address e new standby PLC address old primary address SWP_MB2 BOOL Not used Reserved
57. Primary and Standby Step Action 1 Connect to Primary 2 Access the Command Register system bit SW60 3 3 Reset bit to 0 161 Logic Mismatch 162 Transferring an Application Program with Unity Pro Introduction Overview What s in this Chapter This chapter provides information about the Application Program Transfer feature that enables you to configure the Standby controller from the Primary controller This chapter contains the following topics Topic Page Overview of Application Program Transfer 164 Executing the Application Program Transfer Procedure Using the Command 166 Register Automatic Application Program Transfer 167 Executing the Application Program Transfer Procedure Using the Keypad 168 163 Application Program Transfer Overview of Application Program Transfer Overview Methods of Transferring Programs Validating Transfer Understanding Transfer Time Updating from the Primary The Application Program Transfer feature provides you with the ability to configure the Standby from the Primary controller Use this feature when you reprogram the Primary controller or replace the Standby controller because the process copies the full application program of the Primary to the Standby This feature not only saves time but ensures that the controllers have identical configurations The system transfers the app
58. SBY Standby_PLC_Flag FR_REV1 FirstRevTransReg FR_REV2 SecondRevTransReg 181 Using Modicon Quantum Hot Standby with Unity HSBY EFBs Appearance in Appearance LD REV_XFER_ Instance REV_XFER EN ENO HSBY_ConfFlag Standby_PLC_FirstReg j TO_REV1 HSBY Primary_PLC_Flag Standby_PLC_SecondReg j TO_REV2 PRY Standby_PLC_Flag SBY FR_REV1 FirstRevTransReg FR_REV2 SecondRevTransReg Appearance in IL Appearance CAL REV_XFER_Instance TO_REV1 Standby_PLC_FirstReg TO_REV2 Standby_PLC_SecondReg HSBY gt HSBY_ConfFlag PRY gt Primary_PLC_Flag SBY gt Standby_PLC_Flag FR_REV1 gt FirstRevTransReg FR_REV2 gt SecondtRevTransReg Appearance in Appearance ST REV_XFER_Instance TO_REV1 Standby_PLC_FirstReg TO_REV2 Standby_PLC_SecondReg HSBY gt HSBY_ConfFlag PRY gt Primary_PLC_Flag SBY gt Standby_PLC_Flag FR_REV1 gt FirstRevTransReg FR_REV2 gt SecondtRevTransReg 182 Using Modicon Quantum Hot Standby with Unity HSBY EFBs Parameter description Description of input parameters Parameter Data type Description TO_REV1 INT Describes the first reverse transfer register if this PLC is the standby PLC TO_REV2 INT Describes the second reverse transfer register if this PLC is the standby PLC Description of the output parameters Parameter Data type Meaning
59. Standby with Unity HE CPU 671 60s p 62 The system determines that one of the two Modicon Quantum Hot Standby with Unity HE CPUs will be the Primary controller and the second controller as the Standby The Keypad may provide status information Therefore to view the status use the Modicon Quantum Hot Standby with Unity HE CPU s keypad by selecting Quantum PLC Operations gt PLC Operations Hot Standby gt Hot Standby Order See Using the Modicon Quantum Hot Standby with Unity 140 CPU 671 60 LCD Display Screens p 27 Connect the Modicon Quantum RIO Heads with each other and with the RIO drops as described in Connecting the Remote I O p 63 Using Unity Pro configure a network that is appropriate for the installed backplanes and the cabling Configure the Hot Standby Register for the Modicon Quantum Hot Standby with Unity HE CPU in Unity Pro as described in Accessing the Base Configuration p 74 58 Installation and Cabling Transferring and Sending the Program from Primary to Standby Transfer the program from your PC to High End CPU using the Unity Pro command PLC gt Transfer program to PLC See Overview of Application Program Transfer p 164 Send your program from the Primary to the Standby using the Primary s keypad Select Quantum PLC Operations gt PLC Operations Hot Standby gt Hot Standby Transfer gt Press lt ENTER gt to confirm Transfer gt See Using t
60. System Swapping Network Addresses at Switchover Overview Handling Modbus Addresses at Switchover The following material describes handling network addresses at Switchover A Modicon Quantum Hot Standby with Unity system can communicate data over different network protocols e Modbus e Modbus Plus e TCP IP In a Modicon Quantum Hot Standby with Unity system the Modbus port addresses are e Primary 1 119 e Standby Offset 128 e Maximum address 247 Range 1 247 The Modbus port addresses can be changed using one of two methods e Communication menu in the front panel keypad e Modbus Port tab in the Unity Pro editor Changing addresses Using the Communication menu in the Front Panel Keypad Change address on either Primary Standby 1 Access the front panel keypad of the 1 Access the front panel keypad of the Primary Standby 2 Go to Communication menu 2 Go to Communication menu 3 Go to Serial Port submenu 3 Go to Serial Port submenu 4 Select address 4 Select address 5 Change address 5 Change address 6 Perform application program transfer 6 Perform switchover 7 Verify Standby Modbus address is 128 7 Ensure Standby switched to Primary 8 Perform application program transfer 9 Verify Standby Modbus address is 128 Using the Modbus Port Tab in Unity Pro Editor To change address download application program See Offline Modification of an Application Program and
61. W61 1 0 and SW61 0 1means local PLC is in OFFLINE mode e SW61 1 1 and SW61 0 0 means local PLC is running in Primary mode e SW61 1 1 and SW61 0 1 means local PLC is running in Standby mode Status of remote PLC e SW61 3 0 and SW61 2 1means remote PLC is in OFFLINE mode e SW61 3 1 and SW61 2 0 means remote PLC is running in Primary mode e SW61 3 1 and SW61 2 1 means remote PLC is running in Standby mode SWE61 4 is set 1 whenever a logic mismatch is detected between the Primary and Standby controllers SW61 4 depends on SW60 3 Command Register set 1 SW61 5 identifies the Order reported by the Copro at start time The order depends on the range of the MAC addresses e Ifthe A B designation is A then bit 5 will be set 0 e lf the A B designation is B then bit 5 will be set 1 Note On controller LCD displays eA e B If SW61 14 is set 1 the setting indicates that a logic mismatch has been detected which prevents Unlocated Variables to be transferred from the Primary to Standby If SSW 61 15 is set 1 the setting indicates that the Copro device is set up correctly and working 118 Configuring a Modicon Quantum Hot Standby with Unity System Transferring User Data General At end of scan in a redundant system the Primary must send its data to the Standby in order to keep in ready to assume the role of Primary if the need arises Variab
62. WE60 4 1 Allows the executive to be upgraded on the Standby and the Primary continues to control the process e SWE0 4 0 Allows the executive to be upgraded and to stop the Primary s control of the process Upgrading allows e a Hot Standby system to operate with different versions of the OS running on the Primary and Standby e upgrades without shutting down the process To perform the executive upgrade the Standby must be stopped When started again the Standby operates as a valid Standby See Enabling EXEC Upgrade with Unity Pro p 141 115 Configuring a Modicon Quantum Hot Standby with Unity System System Word SW60 5 System Word SW60 8 Commands Standby to initiate an application transfer e SWE6O0 5 1 means Standby requests an application program transfer from Primary e SW6O0 5 0 is default and no transfer occurs Note SW60 5 is a Monitor Bit SWE60 5 monitors an action Once the action occurs SW60 5 returns to the default which is zero 0 Swap Modbus port e SWE0 8 1 Swaps Modbus addresses on port 1when a switchover occurs Note In a Modicon Quantum Hot Standby with Unity system only Modbus port 1 is available for use 116 Configuring a Modicon Quantum Hot Standby with Unity System Understanding the Unity Status Register Bits in the Hot The Hot Standby Status Register is a readable register located at system word Standby Status SW61 and is
63. ab of the Unity Pro editor 1 2 140 CPU 671 60 X P266 CPU Hot Standby 1Mb Program PCMCIA Ethernet HSBY Fiber optic USB MB MB E Over F Sum Conti MB Modb F Anima wl Hot St F 1 O objects Run Mode Invalidate Keypad _t_ _ Controller A Online v Yes Controller B Online v Standby On Logic Mismatch Swap Address At Switchoverp _ Offline v Modbus Port 1 5 Online w Modbus Port 2 w Modbus Port 3 m State RAM Non Transfer Area Start M 1 Length 0 86 Configuring a Modicon Quantum Hot Standby with Unity System Describing the Hot Standby Tab Description of the Hot Standby tab Item Option Value Description Run Mode Controller A Offline Online Indicates which Controller B Offline Online Controller will be offline and online at the next start Invalidate Keypad Disable Yes is NOT When selected you selected prevent keypad Enable Yes is selected Changes to the Hot Check mark Standby submenu displays Standby On Logic Offline Default If mismatch is Mismatch Offline button detected Standby selected goes Offline Online If button is selected and mismatch is detected Standby remains Standby Swap Address At Modbus Port 1 x When selected Switchover enables Mo
64. acklight will turn on and the Default Screen will stay as the displayed screen If at any time the executive detects an error in the CPU it will display an error message to the LCD and the LCD s backlight will turn on until the error condition disappears 24 Overview Modicon Quantum Hot Standby with Unity Using the Modicon Quantum Hot Standby with Unity 140 CPU 671 60 LED Indicators Overview The Modicon Quantum Hot Standby with Unity 140 CPU 671 60 offers two indicators 1 LCD display screen See Using the Modicon Quantum Hot Standby with Unity 140 CPU 671 60 LCD Display Screens p 27 The default display screen serves as a controller status screen See Understanding the Default Screen p 29 2 LED Indicators See Interpreting the LED Indicators p 26 Position of indicators on Modicon Quantum Hot Standby with Unity 140 CPU 671 60 140 CPU 671 60 HOT STANDBY CONTROLLEI COM STS Mac Address 10 00 Ft AHE HE 1 LCD Display lens cover closed 2 LED Indicators 25 Overview Modicon Quantum Hot Standby with Unity Interpreting the LED Indicators The LEDs provide information CPU 671 60 HSBY Coprocessor firmware LEDs Color Description Indicates COM Yellow Controlled by the Communication activity between Primary and Coprocessor hardware Standby controllers STS Yellow Controlled by t
65. ake online modifications to an application program logic program or project in Procedure the Primary controller follow these steps Step Action 1 Ensure both Primary and Standby controllers are in Run Primary and Run Standby mode 2 Connect to the Primary controller and access the Command Register system bit SWEO 3 3 Set to 1 the Command Register system bit SW60 3 4 Modify online the application program 5 After completing the modifications perform Build Project 6 Ensure both Primary and Standby controllers are in Run Primary and Run Standby mode 7 Perform an application transfer to the Standby Application Program Transfer Method and Logic Mismatch p 159 8 Connect to the new Primary controller and access the Command Register system bit SW60 3 9 Set to 0 the Command Register system bit SW60 3 Note Command Register is returned to 0 from 1 Important See Recommendations for Using Logic Mismatch p 160 Reference 154 Logic Mismatch Offline Modification of an Application Program and Logic Mismatch Executing the Procedure Important Reference To make offline modifications to an application program in either controller follow these steps Step Action 1 Modify offline the application program 2 After completing the modifications perform Build Project and save Note Do NOT use the Rebuild All Project option because using Rebuild All Pr
66. and Standby Schneider Electric recommends using only MAST to transfer data during a scan Tasks are handled singly and sequentially Using MAST is consistent with current Modicon Quantum Hot Standby systems because multi tasking is not provided and data transfer will be synchronized with MAST Using a Modicon Quantum Hot Standby with Unity system in a multitasking environment may cause data to change between scans Because in a multi tasking system events may occur asynchronously to the normal scan Those events may happen at a faster rate the same rate or at a slower rate The result is that data modified by these events can be changed during a transfer Note FAST and AUX can be used Ensure that you both analyze your system needs and account for problems that may arise if you use FAST or AUX 42 Compatibility Differences Restrictions Local I O and Distributed I O Restrictions General Note the two following restrictions e Although local I O and distributed I O DIO can be used in a Modicon Quantum Hot Standby with Unity system they are not considered as part of the redundant system e When either local I O and or distributed I O DIO are used in a Hot Standby system each controller in the configured Hot Standby system controls ONLY its own local I O and or DIO respectively 43 Compatibility Differences Restrictions Understanding Other Module Restrictions
67. anding Application Restrictions 46 39 Compatibility Differences Restrictions Compatibility with Installed Systems Modicon Quantum Legacy Systems Copro and Remote I O Head If you install a Unity Pro executive you have to replace the Legacy CPU 16 and 32 bit and the CHS option module with a Modicon Quantum Hot Standby with Unity 140 CPU 671 60 Otherwise Modicon Quantum Hot Standby with Unity will not be available Note EXISTING FIBER CONNECTIONS Fiber connections used on the CHS module will NOT work with the Modicon Quantum Hot Standby with Unity 140 CPU 671 60 Note CHANGING FROM LEGACY To install a Modicon Quantum Hot Standby with Unity 140 CPU 671 60 controller in the backplane requires two sequential slots Legacy systems required two slots in the backplane but the two slots did not need to be sequential Instead of a Modicon Quantum Hot Standby Option Module 140 CHS 110 00 an embedded coprocessor Copro provides a dedicated communications link transferring data between the Primary and Standby controllers This dedicated link cannot be used for any other communications S908 Remote I O Head Option Modules 140 CRP 93 x00 are required in the system for communicating with the remote I O drops and exchanging status between the Primary and Standby controllers 40 Compatibility Differences Restrictions Understanding System Words and System Bits Ove
68. ary controls the process See Online Modifications to an Application Program in the Primary and Logic Mismatch p 154 e download an offline modified application program to the Standby and perform a switchover to run the modified application program See Offline Modification of an Application Program and Logic Mismatch p 155 Use one of two methods to create a Logic Mismatch condition 1 select Standby on Logic Mismatch select online Hot Standby Tab in the Unity Pro dialog This action requires the application program to be downloaded to the controller 2 set to 1 the Command Register system bit SW60 3 This action MUST be performed online in the Primary controller 147 Logic Mismatch Transferring User Data during a Mismatch Using Care with Logic Mismatch Updating Section Data in an Application Program The table following shows which user data is transferred when a mismatch occurs Data Type Transferred on Logic Mismatch Located variables State RAM Yes Unlocated global variables Yes unless variables exist ONLY in modified controller DFB amp EFB instance data Yes unless data exist ONLY in modified controller SFC variable area Yes unless associated SFC section is modified System Bits and Words Yes WARNING I O MAP HAZARD CONFIGURATION HAZARD A mismatch in either the I O map or the configuration is not allowed under any circumstances
69. ate from Offline to Standby it changes to Secondary accordingly The Secondary NOE now becomes the Primary NOE Primary NOE opens all client connections and listens for all server connections and re establishes those connections 10 Simultaneously Secondary NOE listens for all server connections and re establishes those connections When either the CPU stops or the Hot Standby state goes to offline mode two events occur 1 NOE mode goes to Offline 2 NOE uses the IP Address of the present configuration IP Address Assignment and Going Offline HSBY State IP Address Assigned Is Primary to Offline Configured IP Address if other controller does not go to Primary Standby to Offline Configured IP Address 1 105 Configuring a Modicon Quantum Hot Standby with Unity System IP Address Assignment Configuring the NOE IP Address Restriction The NOE can be configured to work in conjunction with the Modicon Quantum Hot Standby with Unity controller Since the Primary and Secondary controllers must have an identical configuration the configured IP Addresses will be the same The NOE s IP Address is either the configured IP Address or the configured IP Address 1 The IP Address is determined by the current local Hot Standby state In the Offline state the IP Address is determined by whether or not the other controller is in transition to the Primary state Note For a Mod
70. bits Ifthe key switch is in the unlocked position all fields are modifiable 35 Overview Modicon Quantum Hot Standby with Unity Using the System Info Menus and Submenus Structure System Info menus and submenus Quantum System Info gt System Info Stop Code Stop Code gt Description System Info OS Ldr Rev 4 Firmware Info gt Exec Rev HF System Info HW Rev Rev Hardware Info gt SN HEHEHHE Submenu PLC Communications System Info System Info Fields Option Description Screen Displays Available Available Stop Code HEHH shows the machine stop code Description shows the description to the machine stop code Firmware Info HH HH shows the number of OS Loader Revision HE HH shows the number of Exec Revision Hardware Info Rev shows the number of Hardware Revision HAHAH shows the serial number of Hardware All fields are read only 36 Overview Modicon Quantum Hot Standby with Unity Using the LCD Settings Menus and Submenus Structure LCD Settings menus and submenus Quantum LCD Settings gt LCD Settings LCD Contrast 0 is black 100 is green LCD Settings LCD Light On time Off 1 Min 5 Min 10 Min 15 Min Submenu LCD Settings LCD Contrast LCD Screen Fields D
71. both a CPU and a Copro identical versions of the EXEC identical power supplies identical RIO Heads identical cabling and cabling systems identical I O drops identical sequential placement on the backplane The data and illustrations found in this book are not binding We reserve the right to modify our products in line with our policy of continuous product development The information in this document is subject to change without notice and should not be construed as a commitment by Schneider Electric 10 About the Book Related D ment OCuUmenis Title of Documentation Reference Number Quantum with Unity Pro Hardware Reference Manual Electronic Documentation CD UNYUSE909CDM Quantum with Unity Pro Discrete and Analog I O Reference Manual Electronic Documentation CD UNYUSE909CDM Quantum with Unity Pro Experts and Communication Reference Electronic Manual Documentation CD UNYUSE909CDM Quantum Automation Series Hardware Reference Manual 840USE10000 Modbus Plus Network I O Servicing Guide Version 2 0 840USE10400 Remote I O Cable System Planning and Installation Guide Version 890USE10100 3 0 Modbus Plus Network Planning and Installation Guide Version 4 0 890USE10000 User Comments We welcome your comments about this document You can reach us by e mail at techpub schneider electric com About the Book 12 Introducing the Modicon Quant
72. by Copro sends aNo Standby message to the Primary Copro 3 The Standby CPU and the standby copro go offline When Standby Copro fails Stage Description 1 When the Primary CPU communicates with the Standby the Standby Copro reports its error to the Primary The Primary requests the Copro to go offline The Standby Copro will also report its error to the Primary Copro by sending a No Standby message Standby goes offline When the Remote IO Head fails Step Description 1 The CPU stops and reports a RIO failure 2 The CPU reports the error to the Copro 3 The Copro sends aNo Standby command to the Primary 4 The Standby goes offline 129 Maintaining a Modicon Quantum Hot Standby with Unity System Detecting High Speed Data Link HDSL Failures Important Information Facts 1 High speed data link connects the two Copros 2 Using the high speed data link the Primary controller communicates with the Standby every 10 milliseconds 3 Primary sends either 1 data message 2 health message Note If both the Primary and Standby do not hear from each other either station can detect a high speed data link failure 130 Maintaining a Modicon Quantum Hot Standby with Unity System Standby Detects a Failure At first Step Action Result 1 Standby does not hear from the Pri
73. by from stations must have the same application executing a different application program if program transfer of control occurs Note OVERRIDING SAME APPLICATION PROGRAM REQUIREMENT To override the requirement that both controllers have the same application program ensure that the Command Registers SW60 3 is set 1 See System Word SW60 3 p 115 Standby Checks Checking for identical application programs Tor Mismatenes Step Action Result 1 At each scan the application The Standby validates the new program s instruction checksum checksum CKSM against its existing CKSM is transferred from the checksum CKSM Primary to the Standby along with any other necessary data 2 Standby determines if mismatch 1 Mismatch Standby goes Offline occurs 2 No mismatch system operates normally 3 The controller returns to Online and is the Standby as soon as the application programs are identical 135 Maintaining a Modicon Quantum Hot Standby with Unity System Replacing a Faulty Module Important You may replace a faulty module while a system is running Ensure that the module being replaced 1 installs into the Standby backplane 2 resides in the same position in both backplanes 3 is same type of module Same type of module means NOE replaces NOE CRP replaces CRP Note IMPORTANT INFORMATION 1 Perform a switchover if replacing a Primary 2 Do NOT remove a Primary controller under power supply H
74. con Quantum RIO head Coaxial cable with splitters 7A MA 0186 100 trunk terminators 7B 52 0422 000 and tap 7C MA 0185 100 for connecting the RIO heads 6 with the RIO drops 8 The dashed connections represent a redundant connection in the RIO network which is not required for the Modicon Quantum Hot Standby with Unity system Modicon Quantum RIO drop Unity Pro computer connected to both controllers via Modbus or Modbus Plus 9A Optional modules NOMs NOEs if required Overview Modicon Quantum Hot Standby with Unity Software Please note Requirements e CRA modules must have V1 25 or higher of the firmware The Unity Hot Standby system is NOT compatible with previous versions of CRA modules e CRP modules must have V1 14 or higher of the firmware The Unity Hot Standby system is NOT compatible with previous versions of CRP modules 20 Overview Modicon Quantum Hot Standby with Unity Modicon Quantum Hot Standby with Unity 140 CPU 671 60 Components Lens Cover LCD Display Protects and provides access to e Key Switch e Battery e Reset Button Open the lens cover by sliding upwards Has a 2 lines by 16 characters LCD display with a backlight dims and adjustable contrast The backlight turns on when e keypad driver detects a key press e key switch state is changed e error message is displayed on the LCD The backlight dims if e no key switch or keypad activity Backlight dims in 5 sec
75. control at the start of the scan the main CPU asks the Copro to service its requests CPU reports any errors detected If Primary Copro fails Primary Controller operates as a standalone Standalone 1 no working Copro 2 no Hot Standby functionality If an error occurs in either one of two controllers Situation Response Controller with error Reports error to other controller by sending a message through either 1 high speed Copro transfer link 2 RIO link Controller without error Detects error from a timeout which occurs because of no activity on link Note Primary maintains continuous activity on link which ensures Standby can detect an error as soon as possible Facts 1 RAM failure is a hard error 2 Copro detects hard errors Detecting failures If Then Hard error occurs 1 Copro sends atake control command to the Standby 2 Primary Copro stops because of an interface error 127 Maintaining a Modicon Quantum Hot Standby with Unity System Failure Detection in Either Copro Failure Detection by an RIO Head Understanding RIO Head Failure Detecting failures If Then Primary Copro reports any error 1 Primary controller acknowledges the error 2 Primary controller attempts to transfer control to the other controller by sending a take contr
76. cting Standby Controller Copro and RIO Head Failures 129 Detecting High Speed Data Link HDSL Failures 0 130 Detecting Remote I O RIO Link Failures 0 000000 e eee ae 133 Checking for Identical Application Programs Checksum 135 Replacing a Faulty Module 00 e eee eee 136 Troubleshooting the Primary Controller 00 0 eee eee eee 137 Troubleshooting the Standby Controller 00 0 0 eee eee ee 138 Understanding the Modicon Quantum Hot Standby with Unity System Special Features 139 Ata Glance ortho iy tio dai ee ee re eet 139 Enabling EXEC Upgrade with Unity Pro 141 Introduction s 8 Seale Pei e kh faa anes bE ee Re eS 141 Overview of Modicon Quantum Hot Standby with Unity EXEC Upgrade 142 Executing the EXEC Upgrade Procedure 000 eee eee eee 143 Handling Logic Mismatch with Unity Pro 145 INthODUCTION eiaa 3a gle ped Seok Me ie Dee ee kaa A Da eed oa 145 Understanding Modicon Quantum Hot Standby with Unity Logic Mismatch 146 Understanding Switchover Behavior during Logic Mismatch 150 Online or Offline Modifications and Logic Mismatch 152 Online Modifications to an Application Program in the Standby and Logic Mismatch iniae iu ae a Ss ee gd ed EE 153 Online Modifications to an Application Program in the Primary and Logic Mismatch ei tees ope
77. cts as a stand alone system On power cycle the controller that has the lowest MAC address will become the Primary The second system automatically becomes the Standby Note The Modicon Quantum Hot Standby with Unity system supports I O connected to a Remote I O network and Ethernet I O scanning Local I O is not supported in a Modicon Quantum Hot Standby with Unity system environment However local I O can be configured and run but will not have any corresponding backup Required to use a Quantum Modicon Hot Standby with Unity system e Unity Pro 2 0 or higher e CRA firmware Release 1 25 or higher e CRP firmware Release 1 14 or higher Note Configure MB address first time 1 Default MB address 1 new 140 CPU 671 60 from factory 2 Change MB address at first configuration on both controllers Schneider Electric recommends do not change MB address after first configuration because unintended operation may result See Configuring a System with the Unity Pro Tabs and Dialogs p 70 Overview Modicon Quantum Hot Standby with Unity Modicon Quantum Hot Standby with Unity 140 CPU 671 60 Module Overview Illustration The following figure shows the Modicon Quantum Hot Standby with Unity 140 CPU 671 60 module and its components Its HSBY fiber optic communications port differentiates this High End CPU module from the 140 CPU 651 60 140 4 CPU 671 60
78. dbus switchover to occur State RAM Non Transfer Area Start MW MW is not transferred Length Specify the range of the length 1 Enter the appropriate values All values depend on Hot Standby configuration 87 Configuring a Modicon Quantum Hot Standby with Unity System Configuring the PCMCIA Cards Configuring with Unity Pro Allocating memory to the memory card Step Action 1 If not opened open the Local Bus configuration editor Go to the local bus in the Structural View of the Project Browser Open the local bus either by double clicking on the Local Bus or by selecting the Local Bus and executing right click Open A graphical representation of the local bus appears Point to and select either PC CardA 1 slot or PC CardB 2 slot 1 Memory configuration of the PCMCIA card 1 2 Memory configuration of the PCMCIA card 2 Double click or right click either PCMCIA card The New Replace Submodule dialog appears New Replace Submodule PartNumber Description OK ar TSX MDP F 032M ATA PCMCIA Files 32768kb FLASH EPROM FLASH EPROM SRAM SRAM TSX MRP F 0128P SRAM PCMCIA Prog 192kb TSX MRP F 0256P SRAM PCMCIA Prog 384kb TSX MRP C 001M SRAM PCMCIA
79. dee cee aid eye ee aye Pe aia d eae lace Rod 154 Offline Modification of an Application Program and Logic Mismatch 155 Chapter 9 Chapter 10 Appendices Appendix A Switchover Methods and Logic Mismatch 000 ce eee ee eee 157 Application Program Transfer Method and Logic Mismatch 159 Recommendations for Using Logic Mismatch 200 ee eee 160 Transferring an Application Program with Unity Pro 163 Introduction i ws teehee ate a Raa hack Pie Pome RES BAe aa 163 Overview of Application Program Transfer 0 000 cece eee eee 164 Executing the Application Program Transfer Procedure Using the Command Register jain fetish a a ee eed ee ee eh Le big bed EREE EN 166 Automatic Application Program Transfer 0 0 0 cee eee 167 Executing the Application Program Transfer Procedure Using the Keypad 168 Using the Modicon Quantum Hot Standby with Unity EFBs 171 Introd ction s sarreren a occa d Se owsane a Foe ce twa ge ake po eat ean Sueded G8 171 Description HSBY_RD 0000 eee nee 172 Description HSBY ST sos es vet ee ea shee oan diced od Ree p Pee Ba 175 Description HSBY_WR 0 00 c cece eee eens 178 Description REV XFER acces vate us herds WE eee 181 a a aA E a a antersattay sure sah gate sabe a tadoaita ata Sister es a ah es lh aA 185 Appendices for Quantum Hot Standby Planning and Installation Guide 185 Modicon Quantum Ho
80. diagram In addition to the simple logic blocks AND OR etc each function or function block of the program is represented using this graphic form For each block the inputs are located to the left and the outputs to the right The outputs of the blocks can be linked to the inputs of other blocks to form complex expressions FFB Collective term for EF Elementary Function EFB Elementary Function Block and DFB Derived Function block Function see EF Function Block see FBD Diagram G GRAY Gray or reflected binary code is used to code a numerical value being developed into a chain of binary configurations that can be differentiated by the change in status of one and only one bit This code can be used for example to avoid the following random event in pure binary the change of the value 0111 to 1000 can produce random numbers between 0 and 1000 as the bits do not change value altogether simultaneously Equivalence between decimal BCD and Gray Decimal 0 1 2 3 4 5 6 7 8 9 BCD 0000 0001 0010 0011 0100 0101 0110 0111 1000 1001 Gray 0000 0001 0011 0010 0110 0111 0101 0100 1100 1101 l IEC 61131 3 International standard Programmable Logic Controls Part 3 Programming languages IL IL is the abbreviation of Instruction List This language is a series of basic instructions This language is very close to the assembly language used to program processors 202 Glossary INF INT Integer Literals Each in
81. e blank controller which becomes the Standby After application program transfer both controllers have identical application programs This new feature works well when two controllers are at a maximum of 2 Km apart Note Same Configuration The controllers need to have the same configuration with the same PCMCIA cards or without cards 167 Application Program Transfer Executing the Application Program Transfer Procedure Using the Keypad Overview Using the Keypad Transferring the Application Program For specifics on setting Modicon Quantum Hot Standby with Unity state mode order and transfer from the keypad see Configuring a Modicon Quantum Hot Standby with Unity System p 69 To transfer use the front panel keypad on the controller unit Primary or Standby The Primary copies the complete application program and data to the Standby Note CHANGING FROM LEGACY In legacy Quantum Hot Standby systems an application program transfer could be performed ONLY on the Standby controller The Standby requested from the Primary an application transfer The process was performed on the CHS module and required setting the key in the Xfer key position while pushing the update button In Modicon Quantum Hot Standby with Unity an application transfer is performed either e using the command register An application program transfer can be performed at any time e automatically Transfer occurs first
82. e is changed to OFFLINE control switches to the Standby e f the Standby is taken OFFLINE the Primary continues to operate without a backup e OFFLINE mode does not manage the Remot I O RIO Only Primary state manageds the RIO blinking Controller is waiting for configuration Hot Standby 000000 Hot Standby Power Order Order read only B The order comes from the MAC address The controller with the lowest MAC address is A 31 Overview Modicon Quantum Hot Standby with Unity Hot Standby Fields Options Available Description Screen Available Displays Hot Standby Mode Pressing the lt ENTER gt key confirms Transfer modifiable only if the Transfer The transfer initiates e key switch is in the unlocked position e invalidate Keypad is not selected the request for an application program update from the Primary controller Pressing any other key cancels the Transfer request and returns the Hot Standby Transfer menu option screen to the display Hot Standby Diag Order of diagnostic screens varies with may be different from the list here the operation therefore your order Halt User s task in halt mode RIO fails Error reported by RIO head HSBY fails Error reported by optical link Stop Stop command ordered Off keypad Offline command entered on keypad Off sw60 Offline command set in command register Take over Standby
83. efault Behavior at Switchover e Controller A Primary MB address 1 e Controller B Standby MB address 33 1 32 32 Offset Switchover occurs e Controller A new Standby MB address 33 1 32 e Controller B new Primary MB address 1 Note Numerical address of both ports A and B range 1 64 If Primary address 50 corresponding Standby 18 50 32 The Modbus Plus address of the controllers can be changed using the front panel keypad Communication Modbus Plus Modify Address Modbus Plus address swap behavior when addressed is changed Forced Behavior at Switchover e Controller A Primary MB address 1 e Controller B Standby MB address 33 1 32 32 Offset Change address of Primary 5 96 Configuring a Modicon Quantum Hot Standby with Unity System Forced Behavior at Switchover e Controller A Primary MB address 5 e Controller B Standby MB address 33 Perform Application Program Transfer e Controller A Primary MB address 5 e Controller B Standby MB address 37 5 32 Force switchover e Controller A new Standby MB address 37 5 32 e Controller B new Primary MB address 5 If he Modbus Plus address is modified perform an Application Program Transfer See Transferring an Application Program with Unity Pro p 163 Failure to perform a transfer creates a diff
84. er p 114 e Command and Status Registers are no longer stored in the State RAM e Command and Status Registers are accessible in the system words SW60 and SWE61 e Reverse Transfer registers are no longer stored in the State RAM e System automatically allocates system words SW62 and SW63 as Reverse Transfer words e Reverse Transfer words are no longer part of the Non Transfer Area of the 4xxxx registers 71 Configuring a Modicon Quantum Hot Standby with Unity System Changes from LL984 Opening the Editor Dialog Note CHANGING FROM LEGACY e There is no longer a Non Transfer Area for the Oxxx 1xxx and 3xxx registers e Transferring over multiple scans is no longer available In current Modicon Quantum Hot Standby Systems using the CHS option module additional state RAM could be transferred over multiple scans Not transferring over multiple scans minimizes the impact of state RAM transfers In the Unity Pro Modicon Quantum Hot Standby with Unity 140 CPU 671 60 transfer speeds will be much faster and the amount of state RAM used for transfers will be smaller since unlocated data will be used instead After starting Unity Pro go to the Local Bus in the Structural View of the Project Browser Step Action 1 Open the Local configuration editor either by double clicking on the Local Bus or by selecting the Local Bus and executing right click Open A graphical representation of the local
85. erent offset address in the Standby Note SWAPPING ADDRESSES At switchover the Modicon Quantum Hot Standby with Unity system and NOMs swap Modbus Plus addresses almost instantaneously within one or two milliseconds This almost instantaneous switchover means that host devices which are polling the controller should be talking to the Primary controller and that the network should have minimal network interruption during switchover Note EXEC UPGRADE USING OSLOADER When using Modbus Plus communication and OSLoader only address 1 is valid See Executing the EXEC Upgrade Procedure p 143 97 Configuring a Modicon Quantum Hot Standby with Unity System Handling TCP IP Addresses at Switchover When used in a Modicon Quantum Hot Standby with Unity system the Modicon Quantum Ethernet TCP IP network option modules NOE 771 01 and 11 support address swapping at switchover The swapping of IP addresses behaves much like the address swap of the Modbus Plus ports except that the offset is 1 instead of 32 At switchover the modules exchange their IP addresses NOE 771 address swapping occurs automatically and can not be controlled by options selected in any of the tabs of the editor or controlled by turning ON OFF any of the bits in the command register All standard rules apply to IP addressing with the additional restriction that the IP address cannot be greater than 253 or the broadcast address minus 2 Al
86. escription Contrast Screen Available Displays LCD Contrast HHH A lower percent is darker A higher percent is brighter Use the arrow keys to adjust the setting e Up arrow increases percent e Down arrow decreases percent Submenu LCD Settings LCD Light Screen Displays Fields Available Description LCD Light On LCD light remains on permanently or until changed Off LCD light remains off permanently or until changed 1 Min LCD light remains on for one minute 5 Min LCD light remains on for five minutes 10 Min LCD light remains on for ten minutes 15 Min LCD light remains on for fifteen minutes 37 Overview Modicon Quantum Hot Standby with Unity 38 Modicon Quantum Hot Standby with Unity Compatibility Differences and Restrictions Introduction Overview What s in this Chapter In this chapter you will find an overview of compatibilities within a system that has already been installed differences from Legacy Hot Standby systems and restrictions for the Modicon Quantum Hot Standby with Unity system This chapter contains the following topics Topic Page Compatibility with Installed Systems 40 Understanding System Words and System Bits 41 Understanding Multitasking Restrictions 42 Local I O and Distributed I O Restrictions 43 Understanding Other Module Restrictions 44 Understanding USB Link Restrictions 45 Underst
87. fied for 50 19200 kBit s every link Data Bits 8 Stop Bits 1 or2 Parity EVEN ODD NONE Delay ms 1 ms Address 1 247 for Modbus switchover 1 119 Primary 129 247 Standby Head Slot 0 Mode RTU ASCII Protocol RS232 RS485 81 Configuring a Modicon Quantum Hot Standby with Unity System Using the Animation Tab and PLC Screen Dialogs Accessing the To access the Task Realtime clock and Information tabs of the Unity Pro Animation PLC Screen tab Dialogs Step Action 1 Select the Animation tab 2 The PLC screen tab appears automatically Note The dialogs illustrated here are depicted in offline mode When Unity Pro is connected to a PLC the information displayed in these tabs changes Viewing the Task Unity Pro Task tab dialog Tab PLC Screen P El Task Realtime clock Information Events Start reStart Output Fallback Activate or State Warm restart Applied Outputs Disable all Number Cold start Output Fallback r Last Stop 82 Configuring a Modicon Quantum Hot Standby with Unity System Describing the Task Tab Viewing the Realtime Clock Tab Description of the Task tab Item Option Value Description Events State XXX Status information of events available Online Number XXX N A Activa
88. g right click Open A graphical representation of the local bus appears in the configuration editor Select the Modicon Quantum Hot Standby with Unity HE CPU module and right Click The context menu appears Local Bus Bel Bus 1 140 CPU 671 60 01 00 v Cut te eB Copy 5 Paste Delete Module Open Module Move Module Replace Processor HIN Power Supply and IO Budget 4 M Select Open Module The editor appears The Summary tab is default Choose one of these tabs Summary See Using the Summary Tab p 75 Overview See Using the Overview Tab p 76 Configuration See Using the Configuration Tab p 77 Modbus Port See Using the Modbus Port Tab p 80 Animation See Using the Animation Tab and PLC Screen Dialogs p 82 Hot Standby See Using the Hot Standby Tab p 86 74 Configuring a Modicon Quantum Hot Standby with Unity System Using the Summary Tab Viewing Use the Summary tab of the Unity Pro editor to determine if Peer Cop and Hot Standby are enabled 1 2 140 CPU 671 60 Bem P266 CPU Hot Standby 1 Mb Program PCNCIA Ethernet HSBY Fiber optic USB MB MB E Over F Sum Sa Conti MB Modo FF Anima alll Hot st FF VO objects CPU Name Model Quant
89. g the Modicon Quantum Hot Standby with Unity 140 CPU 671 60 Keypad Using the Keys Functionality Key Function To cancel an entry or suspend or stop an action in progress ESC To display the preceding screens successively step up the menu tree aa To confirm a selection or an entry ENTER To set a field on the display into modify mode MOD LED on key active e To scroll through menu options e To scroll through modify mode field options LED flashing key active e Field in modify mode has options to scroll through LED off key inactive e No menu options no field options LED on key active e To move around in a screen field to field e e To go to the sub menu LED flashing key active e To move around ina field that is in modify mode digit to digit LED off key inactive e No sub menu for menu option e No moving around in a screen e No moving around in a field 23 Overview Modicon Quantum Hot Standby with Unity Adjusting the The contrast is adjustable from the keypad when the Default screen is displayed as Contrast follows Step Action 1 Press the MOD key 2 To adjust the contrast darker press 3 To adjust the contrast lighter press 4 To confirm the setting press ENTER Using the Pressing a key will turn on the LCD backlight if it was off When the user presses Backlight the ESC key and the LCD backlight was off the LCD b
90. ge This is the safety alert symbol It is used to alert you to potential personal A WARNING WARNING indicates a potentially hazardous situation which if not avoided can result in death serious injury or equipment damage N CAUTION CAUTION indicates a potentially hazardous situation which if not avoided can result in injury or equipment damage Safety Information PLEASE NOTE Electrical equipment should be serviced only by qualified personnel No responsi bility is assumed by Schneider Electric for any consequences arising out of the use of this material This document is not intended as an instruction manual for untrained persons 2005 Schneider Electric All Rights Reserved About the Book At a Glance Document Scope This guide describes the Modicon Quantum Hot Standby with Unity system consisting of the Unity Pro software the Modicon Quantum Hot Standby with Unity 140 CPU 671 60 power supplies and remote I O RIO This guide describes how to build a Modicon Quantum Hot Standby with Unity system Users of legacy Quantum Hot Standby systems should note that significant differences exist between Unity and legacy systems and where important this guide identifies those differences Note Software Requirements Required to use a Quantum Modicon Hot Standby with Unity system e Unity Pro 2 0 or higher e CRA firmware Release 1 25 or higher e
91. gout if any connection has logged in During a swap the NOE will reset all client connections using a TCP IP reset 109 Configuring a Modicon Quantum Hot Standby with Unity System I O Scanning Service The I O Scanning provides the repetitive exchange of data with remote TCP IP nodes I O devices While the PLC is running the Primary NOE sends Modbus Read Write read or write request to remote I O devices and transfer data to and from the PLC memory In the secondary controller the I O scanning service is stopped When the Hot Standby swap occurs the Primary NOE closes all connections with 1 O devices by sending a TCP IP reset The I O scanning service in this NOE is standby After the swap the new Primary NOE re establishes the connection with each I O devices It restarts the repetitive exchange of data with these re connections The NOE 771 01 and 11 provides the I O scanning feature Configure using either e Unity Pro software e Internal I O Scanner Web page Using either method the configuration and transfer of data between network addresses can be done without using the MSTR IEC function block Note I O SCANNING AND SWITCHOVER WITH CRITICAL APPLICATIONS Account for the following Ethernet I O scanning considerations during a switchover e f MSTR IEC function block is used for TCP IP only some of the Op Code will be used Therefore the block will not complete its transaction and returns error code
92. gram with Unity Pro 163 10 Using the Modicon Quantum Hot Standby with Unity EFBs 171 139 Understanding Modicon Quantum Hot Standby with Unity Special Features 140 Enabling EXEC Upgrade with Unity Pro Introduction Overview What s in this Chapter In this chapter you will find information regarding the EXEC upgrade method for a Modicon Quantum Hot Standby with Unity system Upgrading allows you to update the EXEC for the standby controller while the process is still controlled by the primary controller This chapter contains the following topics Topic Page Overview of Modicon Quantum Hot Standby with Unity EXEC Upgrade 142 Executing the EXEC Upgrade Procedure 143 141 Enabling EXEC Upgrade Overview of Modicon Quantum Hot Standby with Unity EXEC Upgrade Upgrading while Process is Running Upgrading EXEC without Stopping The Executive Upgrade feature allows upgrading the EXEC of the Standby controller while the Primary controller continues to control the process However during the upgrade the system can no longer be considered redundant That is there is no Standby available to assume control if the Primary should fail before the Standby upgrade is complete Under normal operating conditions both controllers in a redundant system must have the same versions of firmware In fact there are checks by the controllers to detect if there is a
93. guration Tab 77 Using the Modbus Port Tab 80 Using the Animation Tab and PLC Screen Dialogs 82 Using the Hot Standby Tab 86 Configuring the PCMCIA Cards 88 Configuring the Modbus Plus Communication Type 90 Setting the Invalidate Keypad Option 92 Swapping Network Addresses at Switchover 94 70 Configuring a Modicon Quantum Hot Standby with Unity System Introducing Unity Pro Overview No Loadables Needed Command Register Changes from Concept Unity Pro software is a fully Windows compatible application Unity Pro supports only the IEC method of configuration with some simplifications e Removes the legacy requirement to reserve the 3xxxx area for transferring unlocated variables Unlocated variables are transferred with the State RAM e Uses system words for the command and status registers which are removed from the State Ram Note CHANGING FROM LEGACY The current Modicon Quantum Hot Standby loadable CHS is no longer needed For Unity Pro Modicon Quantum Hot Standby with Unity systems the control functionality will be embedded in the executive For legacy Modicon Quantum Hot Standby systems Modsoft Concept or ProWORX the CHS module owns the control functionality The Command Register defines the basic operational parameters of a Modicon Quantum Hot Standby with Unity solution The command register s functionality is described in Understanding the Unity Command Regist
94. h Installed Systems 00 000 c eee eee eee 40 Understanding System Words and System BitS 20000000 41 Understanding Multitasking Restrictions aeaaaee 42 Local I O and Distributed I O Restrictions 0 00 e eee eee 43 Understanding Other Module Restrictions 0200ec eee eeee 44 Understanding USB Link Restrictions 0 0 c beeen ee 45 Understanding Application Restrictions 0 0 e eee eee 46 Using IEC Logic and Modicon Quantum Hot Standby with Part Il Chapter 4 Chapter 5 5 1 5 2 INtrODUCTION ao e Ra see Pe A A ee wR eee ee ee 47 Modicon Quantum Hot Standby with Unity and IEC Logic 48 Understanding the Modicon Quantum Hot Standby with Unity State RAM Transfer Processar iana hanes tant etal NLA eh ete a een ae he ee A Na 49 Understanding System Scan Time in Modicon Quantum Hot Standby with Unity Systems 9 t saat tects he ning ae Be oa ee acess meade atonal 50 Transferring Application Data in a Modicon Quantum Hot Standby with Unity Systemin era hace ett a Ses ee ts ee inlet aie Cia Skea oe cuca coe peek 54 Setting up and Maintaining a Modicon Quantum Hot Standby with Unity System 0002200e 55 AbarGlanCe stats or no sg tore anise L E tea E A Ae 55 Setting up Installing and Cabling a Modicon Quantum Hot Standby with Unity System 000 e eee eee 57 InitrOdUCtION ireset is cette Dy eed owt ee a Ee a
95. he Modicon Quantum Hot Standby with Unity 140 CPU 671 60 LCD Display Screens p 27 Note A program can be sent only from the Primary controller to the Standby controller 59 Installation and Cabling Mapping the Backplane Extension Requiring Two backplanes must be configured with identical hardware software and firmware Identical in identical order Then both controllers may function either as a Primary controller Backplanes or as a Standby controller Note INSTALLING CONTROLLERS Schneider Electric recommends referring to Schneider Electric planning and installation guidelines You will find more information in the Quantum Automation Series Hardware Reference Guide 840 USE 100 00 and in Remote I O Cable System Planning and Installation Guide 840 USE 101 00 Noting the The Primary and Standby must belong to the Modicon Quantum Hot Standby with Module Version Unity product family The Modicon Quantum RIO drops can be from Schneider Electric s 800 series of modules 60 Installation and Cabling Installing Components and Modules A Modicon Quantum Hot Standby with Unity system requires two backplanes with at least four slots The backplanes 1 2 must be identically equipped with e Modicon Quantum Hot Standby with Unity 140 CPU 671 60 with integrated coprocessor Copro 3 e Modicon Quantum power supply module 4 e Modicon Quantum RIO Head 5 e Other modules for e
96. he Status of Copro e Blinking e system is redundant and data are exchanged from the Primary to Standby controller e Steady on e system is NOT redundant e Copro booting from power on to end of self tests Steady off e Copro auto tests failed Note No activity returns the LEDs to the default 1 The Modicon Quantum Hot Standby with Unity HE CPU uses an embedded coprocessor Copro to provide a dedicated communications link which transfers data between the Primary and Standby controllers 26 Overview Modicon Quantum Hot Standby with Unity Using the Modicon Quantum Hot Standby with Unity 140 CPU 671 60 LCD Display Screens Overview The controller s LCD displays messages These messages indicate the controller s status There ae four levels of menus and submenus All menus are accessed using the keypad on the front of the controller For detailed information about the menus and submenus see e Using the PLC Operations Menus and Submenus p 30 e Using the Communications Menus and Submenus p 33 e Using the System Info Menus and Submenus p 36 e Using the LCD Settings Menus and Submenus p 37 Structure LCD display menus and submenus Mode State Bat L a me A Quantum Quantum p gt Quantum p gt Quantum 2 PLC Operations gt Communications gt System Info gt LCD Settings gt l l
97. icon Quantum Hot Standby with Unity system the two IP Addresses will be consecutive The following table shows the IP Address assignments Hot Standby State IP Address Primary Configured IP Address Standby Configured IP Address 1 Transition from Primary to Offline Configured IP Address if peer controller does not go to Primary Transition from Standby to Offline Configured IP Address 1 Note Offline Results depend on whether or not the other controller is detected as in transition into the primary state If Current IP is the configured IP Address then change the IP Address to the configured IP Address 1 Note Configuring NOE Do not use either broadcast IP Address or broadcast IP Address 2 to configure a NOE 106 Configuring a Modicon Quantum Hot Standby with Unity System IP Address For continued Ethernet communication the new Primary NOE must have the same Transparency IP Address as the former Primary NOE The IP Address in the Secondary NOE an NOE in the secondary state is IP Address 1 The NOEs integrated into the Modicon Quantum Hot Standby with Unity configuration coordinate this swapping IP Address with the management of Ethernet services used Note Do not use the address IP 1 For a Modicon Quantum Hot Standby with Unity system do not use consecutive addresses of the configured IP Address If you configure the last IP Address 255
98. imary controller failed note controller s status displayed in the HE CPU LCD screen and the RIO Head s status displayed by the RIO Head s LEDs See Troubleshooting the Primary p 137 The Standby controller does not execute the full application program but only the first section and the Standby controller does not control the remote I O but checks out the availability of the Modicon Quantum Hot Standby with Unity equipment Either of the two controllers may function as the Primary controller and the other as the Standby controller Primary and Standby states are switchable Therefore if one of the two controllers is functioning as the Primary controller the other must be in Standby mode Otherwise the second controller is in the default mode which is offline The remote I O is always controlled by the Primary controller 16 Overview Modicon Quantum Hot Standby with Unity Monitoring the System Power Cycle Handling I O Handling Local 1 0 Software Requirements Configuring Modbus Plus MB Addresses The Primary and the Standby controllers communicate with each other constantly to monitor the functionality of the system e f the Primary controller fails the state of the controllers is switched The Standby controller becomes the Primary executes the application program and controls the remote I O e Ifthe Standby controller fails the Primary controller continues to run without redundancy and a
99. ing Change values using the Configuration tab of the editor 1 2 140 CPU 671 60 Belk P226 CPU Hot Standby 1 Mb Program PCMCIA Ethernet HSBY Fiber optic USB MB MB Over Fi Sum Conf MB Moab F Anima dk Hot St FF vO objects m Operating Mode On Cold Start State RAM Automatic start in Run Mem usage 4 M MWi Reset I Ox 4x M 256 MW 1024 m Memory Card f 1x 3x PA SME oan l 256 ww 1024 Usage Data Storage v Size 1 024 KBytes Viewer Application Size 2 048 KBytes B TSX MRP F 008M Usage Data Storage v Size 8 192 KBytes 77 Configuring a Modicon Quantum Hot Standby with Unity System Describing Configuration tab Item Option Value Description Operating Mode On Automatic start in Run x Determines the operating Cold Start MWi Reset on cold start x condition during Cold Start Memory Cards A N A Displays the configuration in the State RAM Mem usage 1 A bar displays percent of memory used M Ox 2 Size of the different memory MW 4x 2 areas i1 2 Note The values for IW and ae i MW have to be divisible by 8 IW 3x 2 Viewer N A Opens the State RAM Viewer tab which displays the allocation of used memory See the illustration following 1 The value expressed as a percentage and displayed on the scale depends on the memory usage of the Hot Standby configuration 2 Enter
100. ing the Modicon Quantum Hot Standby with Unity 140 CPU 671 60 LCD 27 Display Screens 15 Overview Modicon Quantum Hot Standby with Unity Overview of the Modicon Quantum Hot Standby with Unity System Purpose of a Hot Standby System Identical Configurations Primary and Standby Controllers Switchover Capability Use a Modicon Quantum Hot Standby with Unity system when downtime cannot be tolerated Hot standby systems deliver high availability through redundancy A hot standby system consists of two identical configurations e Modicon Quantum 140 CPU 671 60 e Modicon Quantum Power Supply Module e Modicon Quantum RIO Head e Modicon Optional Modules NOE NOM One of the 140 CPU 67160 s acts as the Primary controller and the other acts as the Standby controller The Primary controller runs the application program and operates the remote I O Two backplanes are configured with identical hardware and software One of the programmable logic controllers PLCs functions as the Primary controller and the other as a Standby controller and either controller can be put in the Primary state but the other must be in the Standby state or offline The Primary controller executes the application program controls the remote I O and updates the Standby controller after every scan program cycle If the Primary controller fails the Standby controller takes control within one scan To determine if the Pr
101. injury or equipment damage 156 Logic Mismatch Switchover Methods and Logic Mismatch General Switchover Using Front Panel Keypad Important for Command Register Switchover Switchover can be performed using one of two methods e Hot Standby submenu on the front panel keypad e Command Register either system bit SW60 1 or SW60 2 To force a switchover using the front panel keypad do the following Step Action 1 Access the front panel keypad of the Primary controller Go to PLC Operation menu Go to Hot Standby submenu Go to Hot Standby mode a AJ oO pm Modify Run to Offline Note Ensure that Standby switched to Primary 6 Modify offline to run Note Ensure that the LCD displays Run Standby To perform the switchover using Command Register system bit SW60 1 or SWEO0 2 ensure that following are considered e application program is saved twice Each save uses a different file name e file 1 Saved before modification e file 2 Saved after modification e order of the controller is A or B use one of two methods e Hot Standby submenu on the front panel keypad PLC Operation Hot Standby Hot Standby Order e Unity Pro status dialog refer to the bottom of the Unity Pro window when connected online 157 Logic Mismatch Switchover Using Command Register System Bit SW60 1 or SWE0 2 To force a switchover by setting the
102. ion HSBY_ST_Instance HSBY_ST HSBY THIS_OFF THIS_PRY THIS_SBY REMT_OFF REMT_PRY REMT_SBY LOGIC_OK THIS_ISA THIS_ISB HSBY_ConfigurationFound L PLC_Offline Primary_PLC Standby_PLC L Remote_PLC_Offline PrimaryRemote_PLC StandbyRemote_PLC IdenticalPrograms L HSBY_ModuleSwitchA t HSBY_ModuleSwitchB 175 Using Modicon Quantum Hot Standby with Unity HSBY EFBs Representation Representation in LD HSBY_ST_Instance HSBY_ST EN ENO HSBY_ConfigurationFound CN HSBY T PLC_Offline E THIS_OFF C Primary_PLC Cy THIS_PRY Cae Standby_PLC CF THIS_SBY Remote_PLC_Offline CN REMT_OFF PrimaryRemote_PLC oN REMT_PRY CD StandbyRemote_PLC C5 REMT_SBY C IdenticalPrograms CN LOGIC_OK C HSBY_ModuleSwitchA fy THIS_ISA ae HSBY_ModuleSwitchB THIS_ISB i NF Representation Representation in IL CAL HSBY_ST_ Instance HSBY gt HSBY_ConfigurationFound THIS _OFF gt PLC_Offline THIS_PRY gt Primary_PLC HIS_SBY gt Standby_PLC EMT_OFF gt Remote_PLC_Offline EMT_PRY gt PrimaryRemote_PLC EMT_SBY gt StandbyRemote_PLC OGIC_OK gt IdenticalPrograms THIS _ISA gt HSBY_ModuleSwitcha THIS ISB gt HSBY_ModuleSwitchB T R R R L a 176 Using Modicon Quantum Hot Standby with Unity HSBY EFBs Representation in ST Parameter description Representation HSBY_ST_In
103. l Unlocated variables up to 512 Kb All instances of the DFB and EFB type SFC variable area System Bits and Words Note Forced Bits at Transfer At each scan all forced bits are transferred from the Primary to the Standby State RAM is the memory range which is used for e word orientated input and output components for example analog modules e bit oriented input and output components for example digital modules e binary and word variables for the application program State RAM is assigned the four reference types IW QW l and Q 48 IEC Logic Understanding the Modicon Quantum Hot Standby with Unity State RAM Transfer Process Hot Standby The following illustrates the transfer of data from the Primary to the Standby Copro Transfer Diagram Scan n Primary PLC a IEC Logic Solve Comm Diag IEC Logic Solve Comm Diag IEC Logic Solve Diag CPU gt User Data State RAM Located Unlocated Data max 128 max 512 kByte 640K 640K 640K bytes bytes bytes Copro User Data State RAM Located Unlocated Data max 128 max 512 kByte Standby PUC y y y 640K 640K 640K bytes bytes bytes gt Copro User Data State RAM Located Unlocated Mata Diag Comm Diag Comm Diag CPU a a gt Scan n 1
104. le 1 e Standalone application scan time 80 ms e Data state RAM unlocated variables 100 Kb wm na Result KA o 30ms No impact on scan time data exchange 30 lt 80 ms Example 2 e Standalone application scan time 80 ms e Data state RAM unlocated variables 300 Kb 52 IEC Logic nam sazna Result HSBY impact on scan time 25ms KQO Oms ssa HD a 25 ms Ues LSN JO SUL ues 53 IEC Logic Transferring Application Data in a Modicon Quantum Hot Standby with Unity System Changing from Legacy Modicon Quantum Hot Standby with Unity Memory Consumption Current Modicon Quantum controllers that use the Concept software have an application data transfer limit of approximately 128 Kb This limit includes located data in state RAM and unlocated data To transfer the unlocated data the system must use a part of the 3x area in the state RAM Schneider Electric chose this method to be compatible with the existing CHS option module 140 CHS 110 00 Thus a trade off is necessary the more unlocated data the less state RAM and vice versa In the Modicon Quantum Hot Standby with Unity 140 CPU 671 60 the CHS option module is no longer used Both the controller and Hot Standby functions are in the same unit Thus there is no need to force unlocated data through the 3x area Not forcing means that all of the state RAM can be used as state RAM up to 128 Kb In addition to the sta
105. les The user data that will be transferred includes Instances Bits ocated variables in state RAM Words e All unlocated variables e All instances of DFB and EFB data e SFC states e System Bits and Words 119 Configuring a Modicon Quantum Hot Standby with Unity System Using Initialized Data Loading at Cold start Time Updating Online Handling Problems at Switchover Solving Mismatch Problems The Modicon Quantum Hot Standby with Unity 140 CPU 671 60 supports initialized data Initialized data allows you to specify initial values for the data that are to be loaded at cold start time Declare the variables before a cold start In addition to declaring values before a cold start you can update the initial values online Updating the initial values online creates a mismatch situation in a redundant system Updating the initial values online presents a problem if a switchover occurs to the non updated PLC then you execute a cold start the older initial values will be used Note WINDOW OF TIME Pay attention to the fact that there is a window of time during which a mismatch can occur Mismatches may cause inconsistent operations However logic mismatches cause the same problems Thus value mismatches will be treated in the same way as logic mismatches Value mismatches give the same indications and the same update requirements 120 Configuring a Modicon Quantum
106. lication program over the dedicated Modicon Quantum Hot Standby with Unity communications link In a redundant system this link connects the two Copros Application transfer is always from the Primary to the Standby There are three methods of transferring application programs e Hot Standby submenu on the front panel keypad e Command Register system bit SW60 5 e Automatic transfer Occurs when you start a Hot Standby system for the first time Therefore the Primary automatically transfers the application program to the Standby See Automatic Application Program Transfer p 167 The Standby validates the transferred application program After validating the Standby starts automatically Application Program Transfer time depends on the size of the application program the larger the program the longer the time Application Program Transfer takes a few seconds Note During application program transfer the system can no longer be considered redundant If the Primary should fail before the Standby is ready to assume the role of Primary there is no Standby available An application program update may only be performed from the Primary to the Standby Note UPDATING STANDBYS The Standby controller cannot update the Primary 164 Application Program Transfer Understanding etal ee Note CHANGING FROM LEGACY Legacy Modicon Quantum controllers running Concept have an Applicatio
107. mary on the high speed data link 1 Standby requests the Primary CPU to monitor the RIO link Primary CPU sends a request to the RIO Head When the RIO Head receives the request If Then RIO Head finds the 1 RIO Head assumes that the Primary must be down RIO link not active 2 Standby assumes control RIO Head finds the RIO link is active 1 health message Message received from Primary CPU must be either Messages are sent every 5 milliseconds from Primary RIO Head to Standby RIO Head 2 I O transaction data message Messages are sent from the Primary RIO Head to the I O drops at the request of the controller Facts about the I O 1 If the message is an I O transaction the RIO Head 1 concludes the failure occurred on the high speed data link 2 informs the Primary controller to go to offline 2 If you never configure an I O drop the failure on the high speed data link could cause the Standby to assume control since the Standby RIO head will never receive any I O transaction message 3 After any CPU fails 1 RIO Head will not perform drop communication 2 RIO Head sends only health messages 131 Maintaining a Modicon Quantum Hot Standby with Unity System Standby Assumes Control The Standby becomes Primary Step Action Result 1 After the Primary controller goes offline A health message from the Standby con
108. mode glass fiber for all Recommends Cables Available applications because of the relatively low loss of signal and signal distortion Note Most 62 5 125 um cables are rated at 3 5 dB loss per km 2 Use a 3 mm diameter cable for your Modicon Quantum Hot Standby with Unity system Note The fiber cable clasps used to maneuver the cable into the ports are designed to be used with 3 mm cable Select the cable that meets the demands of your application Wherever possible use a multiconductor cable since the cable is inexpensive and provides a backup in case the cable is cut in the process of pulling From Schneider Electric Part Number Maximum Length 490 NOR 000 03 3 meters 490 NOR 000 05 5 meters 490 NOR 000 15 15 meters 188 Additional Information 140 CPU 671 60 Specifications for Modicon Quantum Hot Standby with Unity Module Specifications Processor Memory Reference Capacity Component Description Communication ports 1 Modbus RS 232 RS 485 1 Modbus Plus RS 485 1 USB 1 Ethernet used as HSBY port Bus current required 1800 mA Max number of NOM NOE CRP 811 and 6 MMS modules supported any combination Key switch Yes Keypad Yes Feature Description Model Pentium Clock speed 266 MHz Coprocessor Yes Built in Ethernet Watchdog timer 250 ms S W adjustable
109. mory Area options Using this option you designate a state RAM address Select one of four reference types e M l IW MW Your choice appears in the Address field of the Address Information area 79 Configuring a Modicon Quantum Hot Standby with Unity System Using the Modbus Port Tab Viewing You may change Modbus communication options using the Modbus Port tab of the Unity Pro editor 1 2 140 CPU 671 60 Ox P266 CPU Hot Standby 1Mb Program PCMCIA Ethernet HSBY Fiber optic USB MB MB lover FR Sum Conti MB Modb FR Anima all Hot St F VO objects Bridge Mode m Modbus Port Baud Data Stop Bits Parity Delay ms Address Head Slot Mode Protocol Bits 1 _ E alt leven v 10 1 olau Rs232_ 2 s600 v alli v Even v 10 1 of fATU_ As232 3 se00 v elli Even v 10 1 ol rtu _ 7 Rs232 Note FINDING MODBUS ADDRESS If you need the Modbus address of the controller go to the 140 CPU 671 60 module and find the address using the keypad See Understanding the Default Screen p 29 80 Configuring a Modicon Quantum Hot Standby with Unity System Describing Modbus Port tab Item Option Value Description Modbus Port Baud 9600 Data must be speci
110. mote Clients Local Clients The Modicon Quantum Hot Standby with Unity solution is a powerful feature of NOEs a feature that increases the reliability of your installation Hot Standby uses a network and using the Hot Standby feature over a network can affect the behavior of e Browsers e Remote and Local clients e I O Scanning service e Global Data service e FTP TFTP server The following are factors you may encounter while using the Modicon Quantum Hot Standby with Unity solution Note In Modicon Quantum Hot Standby with Unity configuration the NOE s I O scanner is enabled If a browser requests a page and during the process of downloading that page an IP Address swap occurs the browser will either hang or time out Click the Refresh or Reload button Hot Standby swaps affect remote clients An NOE will reset under the following conditions e Remote Connection Request during Hot Standby Swap If a remote client establishes a TCP IP connection during a Hot Standby swap the server closes the connection using a TCP IP reset e Hot Standby Swap during Remote Connection Request If a remote client makes a connection request and a Hot Standby swap occurs during the connection request the sever rejects the TCP IP connection by sending a reset e Outstanding Requests If there is an outstanding request the NOE will not respond to the request but the NOE will reset the connection The NOE will do a Modbus lo
111. n Program Transfer limit of 1 megabyte In the Modicon Quantum Hot Standby with Unity 140 CPU 671 60 transfer size depends on the configuration For example using a card bridge you may transfer up to 7 Mb Therefore transfer the complete application program regardless of the size This transfer takes place over multiple scans thus will be broken up into multiple transfer packets 165 Application Program Transfer Executing the Application Program Transfer Procedure Using the Command Register Overview Transferring the Application Program Using Command Register System Bit SW60 5 To transfer use the command register in the Unity Pro software tools The Primary copies the complete application program and data to the Standby To transfer an application program logic program or project to either the Primary or Standby controller using Command Register system bit SW60 5 do the following Step Action 1 Connect to the Primary controller 2 Access Command Register system bit SWE60 5 3 Set bit to 1 Note The process of setting the bit toggles the bit from 0 to 1 and back to 0 166 Application Program Transfer Automatic Application Program Transfer Overview New in a Modicon Quantum Hot Standby system with Unity is automatic application program transfer As soon as a Primary controller detects a blank controller the Primary transfers the program to th
112. n an 8 bit field The DATE type is entered as follows D lt Year gt lt Month gt lt Day gt This table shows the lower upper limits in each field Field Limits Comment Year 1990 2099 Year Month 01 12 The left 0 is always displayed but can be omitted at the time of entry Day 01 31 For the months 01 03 05 07 08 10 12 01 30 For the months 04 06 09 1 1 01 29 For the month 02 leap years 01 28 For the month 02 non leap years see DT Representation of a Double BCD format double integer The Binary Coded Decimal BCD format is used to represent decimal numbers between 0 and 9 using a group of four bits In this format the four bits used to code the decimal numbers have a range of unused combinations 198 Glossary DDT DFB DINT DT Example of DBCD coding e the number 78993016 e iscoded 0111 1000 1001 1001 0011 0000 0001 0110 DDT is the abbreviation of Derived Data Type A derived data type is a set of elements of the same type ARRAY or of various types structure DFB is the abbrevation of Derived Function Block DFB types are function blocks that can be programmed by the user ST IL LD or FBD By using DFB types in an application it is possible to e simplify the design and input of the program e increase the legibility of the program e facilitate the debugging of the program e reduce the volume of the generated code DINT is the abbrevation of
113. ndby CPU 1 function is B on local rack 2 Command Register is selected RUN 0 The PLC with the Hot Standby CPU 1 function is B on local rack 2 Command Register is selected OFFLINE SBY_OFF BOOL 1 The standby PLC switches to the offline mode as soon as both PLCs receive a different program EXC_UPD BOOL 1 Exec Operating system Update in the Standby PLC is possible with the primary PLC still running After Exec Update the standby PLC changes back to the online mode SWP_MB1 BOOL If a switchover has occurred 1 No Swap address of Modbus ports 1 0 Swap address of Modbus ports 1 SWP_MB2 BOOL Not used Reserved SWP_MB3 BOOL Not used Reserved 174 Using Modicon Quantum Hot Standby with Unity HSBY EFBs Description HSBY_ST Function description Representation in FBD This EFB allows you to use the Hot Stand by function It searches together with other procedures in the Hot Standby family the configuration of the respective Quantum PLC for the required components These components always refer to hardware that is actually connected Therefore the correct behavior of this EFB on the simulators cannot be guaranteed The EFB is used to read the IEC Hot Standby status register Sw61 If there is no Hot Standby configuration present the HS BY output is set to 0 EN and ENO can be configured as additional parameters Representat
114. ng F 63 addresses IP 98 100 MAC 98 118 Modbus 94 Modbus Plus 96 143 swapping 98 100 application programs 116 135 161 164 backlights 21 24 backplanes configuring 74 connecting 62 identical 16 19 58 mapping 58 60 base configurations 19 74 blinking indicators 26 137 138 191 Build Project 146 buttons ENTER 23 ESC 23 MOD 23 reset 22 right 23 up 23 C cables coaxial 63 connecting 62 diagrams 64 fiber optic 62 188 topologies 63 checksums transferring 135 validating 135 CKSM 135 clasps fiber optic 188 211 Index clocks real time 84 time of day 121 coaxial splitters 63 cold starts 78 83 120 Com Act errors 137 138 192 command registers 135 161 diagrams 114 commands Copro link 134 monitor RIO 134 No Standby 129 take control 128 communication types 90 communications healthy 134 not healthy 134 compatibility 16 bit 40 32 bit 40 components Unity systems 61 configurations identical 148 contrast adjustments 24 controller failures 138 Copro link commands 134 Copro link requests 134 Copros 40 CRAs software requirements 20 CRPs software requirements 20 D data editor 86 data logging 63 data messages 130 data transfers 48 50 54 data types 148 DFBs 148 diagnostics Hot Standby 32 Unity Pro 125 diagrams command registers 114 Hot Standby systems 19 MAST scans 51 remote I O networks 64 state
115. not receive a valid response from the Standby Primary operates as if 1 no back up available 2 Primary were a standalone Standalone 1 no working Copro 2 no Hot Standby Functionality Errors and switchovers are logged in the diagnostic buffer To view the log Step Action 1 Select Tools Diagnostic Viewer from the main menu 125 Maintaining a Modicon Quantum Hot Standby with Unity System Finding More Refer to the following sections ie ahaa u Type of failure Refer to section Primary controller Detecting Primary Controller Copro and Primary Copro RIO Head Failures p 127 Primary RIO head Standby controller Detecting Standby Controller Copro and Standby Copro RIO Head Failures p 129 Standby RIO head High speed data link failures Detecting High Speed Data Link HDSL Failures p 130 Remote I O link Detecting Remote I O RIO Link Failures p 133 Application program checksum failures Checking for Identical Application Programs Checksum p 135 126 Maintaining a Modicon Quantum Hot Standby with Unity System Detecting Primary Controller Copro and RIO Head Failures Understanding CPU to Copro Communication Failure Detection between Two Controllers Failure Detection within One CPU Hard Errors Facts 1 On every scan CPU communicates with Copro 2 Main CPU executes the Hot Standby
116. oject will cause the Standby to go offline when the application program is downloaded 3 Ensure both Primary and Standby controllers are in Run Primary and Run Standby mode 4 Connect to the Primary controller and access the Command Register system bit SWEO 3 Set to 1 the Command Register system bit SW60 3 Open the modified program and connect to the Standby controller Download the program and select RUN Note Check your controller s state and ensure state is Run Standby 8 Ensure both Primary and Standby controllers are in Run Primary and Run Standby mode 9 Perform a switchover See Switchover Methods and Logic Mismatch p 157 Note Ensure Standby switched to Primary 10 Perform application transfer to Standby Application Program Transfer Method and Logic Mismatch p 159 11 Connect to the new Primary controller and access the Command Register system bit SWE60 3 12 Set to 0 the Command Register system bit SW60 3 Note Command Register is returned to 0 from 1 See Recommendations for Using Logic Mismatch p 160 155 Logic Mismatch Important WARNING IMMEDIATE CONTROL OF PROCESS Once a new application program is switched to the Standby the Standby takes control of the process e Ensure that you understand the 1 operation of your process 2 modifications made e Monitor all modifications to the application program Failure to follow this precaution can result in death serious
117. ol command to the Standby through the RIO link Primary Copro does not respond within 1 Primary controller acknowledges the error 5 milliseconds 2 Primary controller attempts to transfer control to the other controller by sending a take control command to the Standby through the RIO link Primary Copro sends a take control 1 Primary Copro relinquishes control command to the other Copro 2 Primary Copro does not expect any response Standby copro experiences an error 1 Standby controller reports the error by sending a No Standby message 2 Standby controller goes offline Table with two columns If RIO Head Then Primary Controller Responds Releases control and the Standby station becomes a Standalone Standalone 1 no working Copro 2 no Hot Standby functionality Does NOT respond Continues to scan the I O If the RIO Head fails Main CPU times out when it fails to communicate with the RIO Head Main CPU stops Main CPU reports RIO failure to log Main CPU reports RIO failure error to the Copro oa AJOIN Copro goes offline 128 Maintaining a Modicon Quantum Hot Standby with Unity System Detecting Standby Controller Copro and RIO Head Failures Standby CPU Failure Standby Copro Failure Standby RIO Head Failure When Standby CPU fails Stage Description 1 The Standby CPU reports errors to the Standby Copro 2 The Stand
118. on bus controllers The NOE Hot Standby allows automatic IP Address swap Both controllers are configured identically One controller is the Primary NOE the other controller the Secondary NOE In case of a failure the controllers switchover and the system recovers The NOEs coordinate the swapping of IP addresses After closing both the client and the server connections each NOE sends a swap UDP message to its peer NOE The sending NOE then waits a specified timeout 500 ms for the peer swap of UDP messages Either after receiving the messages or after a timeout the NOE changes its IP address Note NOEs must communicate with each other in order to swap IP Addresses Schneider Electric recommends that you connect the primary and Secondary NOEs to the same switch because e Communication failures between the NOEs increases the time to swap e Connecting two NOEs to the same switch minimizes the probability of a communication failure Note Schneider Electric recommends that a switch not a hub is used to connect the NOEs to each other or to the network Schneider Electric offers switches please contact a local sales office for more information The NOE waits for either a change in the controller s Hot Standby state or the swap of UDP messages Then the NOE performs one of two Hot Standby actions If the NOE 1 Detects that the new Hot Standby state is either primary or standby The NOE changes the IP address
119. on the modification different behaviors occur Modification Effect Only code changed same variables All the variables exchanged between the controllers are equal Variables added to the initial Primary Variables are not used by the new Primary Variables deleted from the initial Primary New Primary executes application program using the latest values for these variables Variables added to the initial Standby New Primary executes application program using initial values for these variables Variables deleted from the initial Standby New Primary will not use these variables 150 Logic Mismatch Modifying an SFC Section with Unity Pro The SFC code generation process does not generate direct executable code but generates a set of data used by the SFC interpreter in the controller s OS to compute the next state As with Concept Unity Pro e does not maintain the equality between the two application programs when a modification of a SFC section occurs e does execute an SFC section by restarting the controller from its initial state after a switchover When a SFC section is modified in the Primary its data are not transferred to the Standby When a transfer of logic occurs from the Primary to the Standby the first section of the logic is diagnostic information Note SFC Programming Language Schneider Electric recommends not using the SFC programming language
120. onds e error message is generated Backlight remains on until the error is corrected and the error message stops 2 Lines by 16 characters LCD 21 Overview Modicon Quantum Hot Standby with Unity Key Switch Keypad Reset Button Use the key switch as a security feature and memory protection switch The key switch has two positions locked and unlocked Key position PLC operation unlocked all system menu operations are able to be invoked and all changeable module parameters are able to be modified by the Ta operator via the LCD and keypad memory protection is OFF locked no system menu operations are able to be invoked and all module parameters are read only a memory protection is ON Switching the key switch position from locked to unlocked or vice versa will turn on the LCD s backlight The Modicon Quantum Hot Standby with Unity 140 CPU 671 60 keypad consists of five keys that are mapped to a hardware address 5 key keypad with 2 LEDs 1 1 5keys 2 2LEDs Use the keys on the keypad to access the Modicon Quantum Hot Standby with Unity set of system menus which enable you to e perform PLC operations for example Start PLC Stop PLC e display module parameters for example communications parameters Forces a cold start of the PLC 22 Overview Modicon Quantum Hot Standby with Unity Operatin
121. op Stop Run Run Run Run 104 Configuring a Modicon Quantum Hot Standby with Unity System Hot Standby Switchover Going to Offline The following steps describe how NOEs coordinate the Hot Standby switchover Step Action 1 NOE A installed in a HSBY rack detects that its local controller changed from Primary to Offline 2 NOE A changes its HSBY state from Primary to Offline with the same Ethernet services running starts its watch dog timer with 500 ms timeout setting and expects from its peer NOE a UDP request to swap the IP Address 3 NOE B installed in peer HSBY rack detects that its local controller changed state from Secondary to Primary 4 NOE B stops all Ethernet services sends a UDP request to its peer NOE NOE A for the synchronization of the IP Address swap starts its watch dog timer with 500 ms timeout setting and then waits for an UDP response from its peer NOE 5 Once NOE A receives the UDP request from NOE B or after its watch dog timer times out it stops all Ethernet services sends a UDP response to NOE B no UDP response is sent to NOE B for watch dog timeout case swaps IP Address as Secondary and starts Secondary services 6 As soon as NOE B receives the UDP response from NOE A or after its watch dog timer times out it swaps IP Addresses and starts Ethernet services as Primary 7 After NOE A senses that its local controller changes st
122. opics Chapter Topic Page Setting Up the Modicon Quantum Hot Standby with Unity System 58 Mapping the Backplane Extension 60 Connecting Two Modicon Quantum Hot Standby with Unity HE CPU 671 60s 62 Connecting the Remote I O 63 Testing the Modicon Quantum Hot Standby with Unity System 66 57 Installation and Cabling Setting Up the Modicon Quantum Hot Standby with Unity System Overview Mapping the Backplane Extensions Connecting Two High End CPUs Establishing the Primary and Standby Conirollers Connecting the Remote I O Configuring in Unity Pro Schneider Electric is a leader in offering fault tolerant redundant systems Hot Standby Setting up a Modicon Quantum Hot Standby with Unity system involves a number of processes summarized in the following paragraphs here and explained in detail elsewhere A Modicon Quantum Hot Standby with Unity requires two backplanes with at least four slots You must map the two backplanes in an identical manner e same Modicon Quantum Hot Standby with Unity HE CPU with integrated coprocessor Copro same firmware same revision level same Modicon Quantum power supply module e same Modicon Quantum RIO Head And if other modules are used for example local I Os NOMs NOEs those modules must be identical Connect the two Modicon Quantum Hot Standby with Unity High End CPUs with a fiber optic cable as described in Connecting Two Modicon Quantum Hot
123. or 1 34e 12 1 0E 6 or1 0e 6 1 234E6 or1 234e6 SFC Single Token ST SFC is the abbreviation of Sequential Function Chart SFC enables the operation of a sequential automation device to be represented graphically and in a structured manner This graphic description of the sequential behavior of an automation device and the various situations which result from it is performed using simple graphic symbols Operating mode of an SFC chart for which only a single step can be active at any one time ST is the abbreviation of Structured Text language Structured Text language is an elaborated language close to computer programming languages It enables you to structure series of instructions 206 Glossary STRING A variable of the type STRING is an ASCII standard character string A character string has a maximum length of 65534 characters T TIME The type TIME expresses a duration in milliseconds Coded in 32 bits this type Time literals TIME_OF_DAY TOD makes it possible to obtain periods from 0 to 2 32 1 milliseconds The units of type TIME are the following the days d the hours h the minutes m the seconds s and the milliseconds ms A literal value of the type TIME is represented by a combination of previous types preceded by T t TIME or time Examples T 25hi5m t 14 7S TIME 5d10h23m45s3ms The units of type TIME are the following the days d the hours h the minute
124. ords can be used by the application program in the first section to register diagnostic information The data coming from the Standby are transferred at each scan and are available to the Primary 113 Configuring a Modicon Quantum Hot Standby with Unity System Understanding the Unity Command Register Setting the Bits The Command Register defines the operating parameters of a Hot Standby inthe Command application for both the Primary and Standby and is located at system word SWE60 Register At each scan the Command Register is replicated and transfers data from the Primary to the Standby Transfer occurs only from Primary to Standby Any changes made to the Command Register on the Standby will have no effect because the values transferred from the Primary overwrite the values in the Standby The following illustration identifies the operating options provided by the Command Register Disables LCD Invalidate Keypad 0 Enables LCD Invalidate Keypad 1 Sets Controller A to OFFLINE mode 0 Sets Controller A to RUN mode 1 Sets Controller B to OFFLINE mode 0 _ Sets Controller B to RUN mode 1 Forces Standby offline if there is a logic mismatch 0 Does not force Standby offline if there is a logic mismatch 1 Allows exec upgrade only after application stops 0 Allows exec upgrade without stopping application 1 MSB 15 14 13 12 14 10 9 8 7l6 5 4 1 3 2 1 Jo LSB
125. ot Swap 136 Maintaining a Modicon Quantum Hot Standby with Unity System Troubleshooting the Primary Controller Troubleshooting the Primary To determine which component failed note controller s status displayed in the HE CPU LCD screen and the RIO Head s status displayed by the RIO Head LEDs Controller Status RIO Head Status Failure Type Description Stop All LEDs off except Controller An Interface error occurred READY on and Com Act blinks four times Offline All LEDs off except Fiber Optic A Com Act error occurred READY on connection between both controllers Stop All LEDs off except RIO Head A Com Act error occurred READY on and Com Act displays error pattern Stop READY on and Com RIO Cable In a dual cable system if only Act blinks four times Failure at one cable fails the Error A or Primary End Error B indicator on the RIO Head lights instead of stopping the system and the system continues to operate When the RIO cable fails at the Primary end input data may be reset to 0 for one scan because the communication failure to the drop occurs before the broken link is detected 137 Maintaining a Modicon Quantum Hot Standby with Unity System Troubleshooting the Standby Controller Troubleshooting To determine which component failed note controller s status displayed in the HE the Standby CPU LCD screen and the R
126. pdates the PLC with the time set by the user Unity Pro Information tab dialog PLC Screen Ei il Task Realtime clock A information LL Z SYSTEM INFORMATION PLC IDENTIFICATION MEMORY APPLICATION 4 IDENTIFICATION OPTION HOTSTANDBY 84 Configuring a Modicon Quantum Hot Standby with Unity System Describing the Information Tab Description of the Information tab Item Option Value Description System PLC Identification PLC Range Only Online Information Hardware ID available Processor Name Processor Version Network address PLC Memory Application Identification Name Creation Product Date Modification Product Date Version Signature Application Option Empty Terminal Support Upload Information Comments Animation Table Global Protection Section Protection Application Diagnostic Forced Bits Hot Standby Bit Number Status Register PLC Mode Other PLC Mode PLCs matching Logic PLC switch Copro Health Hot Standby Capability 85 Configuring a Modicon Quantum Hot Standby with Unity System Using the Hot Standby Tab Viewing the Hot Standby Tab Configure Hot Standby values in the Hot Standby t
127. r 137 Troubleshooting the Standby Controller 138 123 Maintaining a Modicon Quantum Hot Standby with Unity System Verifying the Health of a Modicon Quantum Hot Standby with Unity System Generating and Sending Health Messages Performing Automatic Confidence Tests Conducting Startup Tests Conducting Run Time Tests The Modicon Quantum Hot Standby with Unity modules exchange a health message approximately every 10 ms If the Primary has an error the Standby is notified and assumes the Primary role If the Standby has an error the Primary continues to operate as a standalone The RIO head processors periodically verify communication with one another The Primary sends a health message to the Standby either 1 every 10 milliseconds when no other data is being sent on the high speed Copro link 2 every 5 milliseconds if no communication is required with any drop on RIO link If the Standby never receives any message on either link the Standby will try to determine the cause of the failure and assumes control if necessary If the Primary does not receive a valid response from the Standby the Primary will operate as if there was no back up available as if the Primary were a standalone The system automatically performs two kinds of confidence tests on the Modicon Quantum Hot Standby with Unity Copro e Startup tests e Run time tests Startup confidence testing on the Modicon Quantum Hot S
128. ration of the respective Quantum PLC for the required components These components always refer to hardware that is actually connected Therefore the correct behavior of this EFB on the simulators cannot be guaranteed The EFB HSBY_WR is used to set different Hot Standby Modes permitted for Hot Standby Setting the respective modes means a change in the Hot Standby command register sw60 which is carried out automatically by the function block If there is no Hot Standby configuration the HSBy_ConfigurationFound output is set to 0 otherwise it is set to 1 Note This function only affects the primary CPU EN and ENO can be configured as additional parameters Representation HSBY_WR_Instance HSBY_WR InvalidateKeypad INV_KEY HSBY HSBY_ConfigurationFound PLC_A_Running PCA_RUN PLC_B_Running PCB_RUN SwapAddressModbusPort 1 4 SWP_MB1 1 SWP_MB2 SWP_MB3 178 Using Modicon Quantum Hot Standby with Unity HSBY EFBs Representation Representation in LD HSBY_WR_Instance HSBY_WR EN ENO InvalidateKeypad HSBY_ConfigurationFound INV_KEY HSBY gt PLC_A_Running PCA_RUN PLC_B_Running PCB_RUN SwapAddressModbusPort1 SWP_MB1 SWP_MB2 SWP_MB3 Representation Representation in IL CAL HSBY_WR Instance INV_KEY InvalidateKeypad PCA_RUN PLC_A Running PCB_RUN PLC_B Running SWP_MB1 SwapAddressModbus
129. ress o Download the OS to the Standby 10 Download application program to the Standby Note Ensure that you download a valid application program 11 Ensure that the Modbus Plus address is the same as the address noted in Step 3 12 Reconnect fiber optic cable to both controllers Note Primary operates with a Standby 13 Put in RUN mode Ensure Primary and Standby are in RUN Primary and RUN Standby mode 14 Perform switchover Note Ensure Standby becomes Primary 15 Repeats Steps 3 through 12 to the new Standby Ensure Primary and Standby are in RUN Primary and RUN Standby mode 16 Connect to the new Primary and access the Command Register system bit SWE0 4 set to 0 To upgrade a Modicon Quantum Hot Standby with Unity EXEC without shutting down the process the current application program must be executable by the new EXEC Observe this requirement when installing minor revisions targeted for bug fixes or minor enhancements When a major function enhancement needs to be made maintaining this compatibility may not be possible In this case to perform an EXEC upgrade requires a system shut down 144 Handling Logic Mismatch with Unity Pro Introduction Overview What s in this Chapter in Unity Pro This chapter provides information about using the Logic Mismatch feature available This chapter contains the following topics
130. rview System Word SWED System Word SW61 System Word SW62 and SWE3 In conforming with IEC standards Unity uses global objects called system bits and system words Users of legacy Schneider Electric products may be familiar with registers 984LL notation Regardless of notation the behavior remains the same System Word SW60 can be used to read from and to write to the Modicon Quantum Hot Standby with Unity Command Register Note SW60 is described using the IEC convention System Word SW61 can be used to read the contents of the Modicon Quantum Hot Standby with Unity Status Register Note SW 61 is described using the IEC convention System Words SW62 and SW63 are reverse registers reserved for the Reverse Transfer process Both reverse registers can be written to the application program first section of the Standby controller and are transferred at each scan to the Primary controller 41 Compatibility Differences Restrictions Understanding Multitasking Restrictions General MAST Asynchronous Events FAST and AUX In a Modicon Quantum Hot Standby with Unity system the Standby controller is kept ready to assume the role of the Primary controller by having the same application loaded in the Standby and by receiving from the Primary once per scan a copy of the Primary s data During the scan there is a tight synchronization between the Primary
131. s Topic Page Description HSBY_RD 172 Description HSBY_ST 175 Description HSBY_WR 178 Description REV_XFER 181 171 Using Modicon Quantum Hot Standby with Unity HSBY EFBs Description HSBY_RD Function description Representation in FBD This EFB allows you to use the Hot Standby function It searches together with other EFBs in the Hot Standby family the configuration of the respective Quantum PLC for the required components These components always refer to hardware that is actually connected Therefore the correct behavior of this EFB on the simulators cannot be guaranteed The HSBY_RD EFB independently checks if a Hot Standby configuration exists sw60 If a configuration is present the contents of the command register are given and the HSBy output is set to 1 If there is no Hot Standby configuration present the HSBY_ConfigurationFound output is set to 0 EN and ENO can be configured as additional parameters Representation HSBY_RD_ Instance HSBY_RD HSBY HSBY_ConfigurationFound INV_KEY InvalidateKeypad PCA_RUN PLC_A_ Running PCB_RUN PLC_B_Running SBY_OFF StandbyOff EXC_UPD ExecUpdate SWP_MB1 SwapAddressModbusPort SWP_MB2 SWP_MB3 172 Using Modicon Quantum Hot Standby with Unity HSBY EFBs Representation inLD Representation in IL Representation in ST Representation
132. s If the cable is not connected properly the Modicon Quantum Hot Standby with Unity HE CPU 671 60s cannot communicate and the Hot Standby system will not function Therefore the Primary operates without a backup and the Standby remains offline Fiber optic cables are sold separately Model Description 490NOR0003 3 m MTRJ MTRJ 490NOR0005 5 m MTRJ MTRJ 490NOR0015 15 m MTRJ MTRJ Controllers connected by a crossed fiber optic cable PC CardB PC CardB JUUUU Mac Address Mac Address Q pO OO HHEHHEHHEHHE pO OO HEHHE HHE HHE Note REDUCING FAILED COMPONENTS Hubs and switches are not allowed as part of the fiber optic link Therefore the fiber connection between Primary and Standby must be a direct cable connection which reduces the components that could fail in the redundant system However the Primary and Standby backplanes may be placed as much as 2 km apart If you will be placing the modules more than 15 m apart use 62 5 125 micrometer cable with MTRJ type connectors Refer to Modicon Quantum Hot Standby with Unity Additional Information p 187 for details 62 Installation and Cabling Connecting the Remote I O Connecting In each configuration Cables to e The cables connecting the RIO head processors to the RIO network have to be Remote I O fitted with self terminating F adapters e An MA 0186 10
133. s m the seconds s and the milliseconds ms A literal value of the type TIME is represented by a combination of previous types preceded by T t TIME or time Examples T 25hi5m t 14 7S TIME 5d10h23m45s3ms see TOD TOD is the abbreviation of Time of Day The TOD type coded in BCD in 32 bit format contains the following information e the hour coded in a 8 bit field e the minutes coded in an 8 bit field e the seconds coded in an 8 bit field Note The 8 least significant bits are unused The Time of Day type is entered as follows TOD lt Hour gt lt Minutes gt lt Seconds gt This table shows the lower upper limits in each field Field Limits Comment Hour 00 23 The left 0 is always displayed but can be omitted at the time of entry Minute 00 59 The left 0 is always displayed but can be omitted at the time of entry Second 00 59 The left 0 is always displayed but can be omitted at the time of entry 207 Glossary Token TOPO_ADDR_TY PE Example TOD 23 59 45 An active step of an SFC is known as a token This predefined type is used as output for READ_TOPO_ADDR function This type is an ARRAY 0 4 OF Int You can find it in the libset in the same family than the EFs which use it U UDINT UDINT is the abbreviation of Unsigned Double Integer format coded on 32 bits unsigned The lower and upper limits are as follows 0 to 2 to
134. section and transition variables The process of updating the application program global data in a Hot Standby system affects e Declared variables All declared variable will be updated on every scan as long as they are declared on both controllers e Updating Standby If a complete application program transfer is done to the controller that did not receive the modified changes then both controllers will have equal application programs and the Standby controller is fully updated e Deleted and redeclared variables If due to a modification a global variable has been deleted first and then redeclared this variable would be treated as a NEW variable even if the same name is used The update procedure must be followed to bring the controllers to an equalized state Note GLOBAL DATA VARIABLES The system reserves space for these variables whether they are used in the controller s application program or not Unused variables consume space and require time to be transferred from the Primary to the Standby Therefore in the Primary s application program Schneider Electric does not recommend using variables that are defined but not used 149 Logic Mismatch Understanding Switchover Behavior during Logic Mismatch Modifying the If a switchover occurs during logic mismatch the new Primary will execute its own Application application program with the data received from the other controller Variables Depending
135. service The NOE does not publish the local variable during a swap And after the swap the new Primary NOE starts to publish application variables and to receive the subscription variables The File Transfer Protocol Trivial File Transfer Protocol FTP TFTP server is available as soon as the module receives an IP address Any FTP TFTP client can logon to the module Access requires the correct user name and password Modicon Quantum Hot Standby with Unity allows only one active FTP TFTP client session per NOE module When the Hot Standby swap occurs the Primary and Secondary NOEs close the FTP TFTP connection If a user sends an FTP TFTP request during the swap the communication is closed Whenever you re open communication you must re enter a user name and a password 111 Configuring a Modicon Quantum Hot Standby with Unity System 5 3 Configuring Registers with Unity Pro At a Glance Purpose This material describes configuring a Modicon Quantum Hot Standby with Unity system by selecting options that affect the registers You may want to use this method if your system has specific configuration needs What s in this This section contains the following topics Section Topic Page Understanding the Non Transfer Area Transferring State RAM and Reverse 113 Transfer Words Understanding the Unity Command Register 114 Understanding the Unity Status Register 117 Transferring User Data 119
136. so no other device should be assigned the configured IP 1 address Note NOE 771 01 and 11 ADDRESS SWAP e NOE 771 01 and 11 are the only Ethernet option modules that support the IP address swap in Modicon Quantum Hot Standby with Unity system V2 0 e NOE 77101 and 11 modules must be configured in the same slot of the Primary and Standby backplanes e NOE 771 01 11 requires minimum firmware revision 2 0 or higher 98 Configuring a Modicon Quantum Hot Standby with Unity System 5 2 Configuring a NOE with Unity Pro At a Glance Purpose This material describes configuring a NOE a Quantum Ethernet module using Unity Pro For a complete description of all models of the NOE see the Quantum NOE 771 xx Ethernet Modules User Guide 840 USE 116 00 What s in this This section contains the following topics Section Topic Page Overview of Modicon Quantum Hot Standby with Unity Solution for NOEs 100 NOE Operating Modes and Modicon Quantum Hot Standby with Unity 102 IP Address Assignment 106 Address Swap Times 108 Network Effects of Modicon Quantum Hot Standby with Unity Solution 109 99 Configuring a Modicon Quantum Hot Standby with Unity System Overview of Modicon Quantum Hot Standby with Unity Solution for NOEs Please Note Description of the Hot Standby Solution The Modicon Quantum Hot Standby with Unity system supports up to six NOE 771 Ethernet adapters
137. stance HSBY gt HSBY_ConfigurationFound A m THIS OFF gt PLC_Offline THIS_PRY gt Primary_PLC THIS _SBY gt Standby_PLC REMT_OFF gt Remote_PLC_Offline REMT_PRY gt PrimaryRemote_PLC REMT_SBY gt StandbyRemote_PLC LOGIC_OK gt IdenticalPrograms THIS _ISA gt HSBY_ModuleSwitchaA THIS ISB gt HSBY_ModuleSwitchB m7 fi Description of output parameters Parameter Data type Meaning HSBY BOOL 1 Hot Standby configuration found THIS_OFF BOOL 1 This PLC is offline THIS_PRY BOOL 1 This PLC is the primary PLC THIS_SBY BOOL 1 This PLC is the standby PLC REMT_OFF BOOL 1 The other remote PLC is offline REMT_PRY BOOL 1 The other PLC is the primary PLC REMT_SBY BOOL 1 The other PLC is the standby PLC LOGIC_OK BOOL 1 The programs for both PLCs are identical and Logic Mismatch is active THIS_ISA BOOL 1 This PLC chose the CPU with the lower IP address between both Hot Standby CPUs This is the Hot Standby CPU A THIS_ISB BOOL 1 This PLC chose the CPU with the higher IP address between both Hot Standby CPUs This is the Hot Standby CPU B 177 Using Modicon Quantum Hot Standby with Unity HSBY EFBs Description HSBY_WR Function description Representation in FBD This EFB allows you to use the Hot Standby function It searches together with other EFBs in the Hot Standby family the configu
138. struction is composed of an instruction code and an operand Used to indicate that a number overruns the allowed limits For a number of Integers the value ranges shown in gray are as follows 74 E i 7 E INF 3 402824e 38 1 1754944e 38 0 0 1 1754944e 38 3 402824e 38 When a calculation result is e less than 3 402824e 38 the symbol INF for infinite is displayed e greater than 3 402824e 38 the symbol INF for infinite is displayed INT is the abbreviation of single integer format coded on 16 bits The lower and upper limits are as follows 2 to the power of 15 to 2 to the power of 15 1 Example 32768 32767 2 1111110001001001 16 9FA4 Integer literal are used to enter integer values in the decimal system The values can have a preceding sign Individual underlines _ between numbers are not significant Example 12 0 123 _456 986 IODDT IODDT is the abbreviation of Input Output Derived Data Type The term IODDT designates a structured data type representing a module or a channel of a PLC module Each application expert module possesses its own IODDTs K Keyword A keyword is a unique combination of characters used as a syntactical programming language element See annex B definition of the IEC standard 61131 3 All the key words used in Unity Pro and of this standard are listed in annex C of the IEC standard 61131 3 These keywords cannot be used as identifiers in your program names of
139. switched to Primary mode Run Run command ordered Plug amp Run Standby plugged and started Power up User powered up controller 32 Overview Modicon Quantum Hot Standby with Unity Using the Structure Communications menu and submenus structure Communications Menus and Quantum Submenus PLC Communications gt Communications TCP IP Ethernet IP Address TCP IP Ethernet gt IP Address gt HHH HHE HH TCP IP Ethernet Subnet Mask Subnet Mask gt H HHE HEH HH TCP IP Ethernet IP Gateway IP Gateway gt HHEH HHH HH TCP IP Ethernet MAC Address MAC Address gt HH HH HE HH HH Communications MB Address Modbus Plus gt Modbus Plus State Communications Mode Protocol Adr Serial Port Serial Port gt Rate Par DB SB gt RS Mode RS 232 Serial Port Protocol Modbus Serial Port Unit Address 1 Serial Port Baudrate 9600 Serial Port Parity Even Serial Port Databits RTU 8 Serial Port RS Mode RS 232 Serial Port Stopbits 1 33 Overview Modicon Quantum Hot Standby with Unity Submenu PLC Communications TCP IP Ethernet TCP IP Ethernet Screen Displays Fields Available Options Available Description
140. t Standby with Unity Additional Information sa icceene ieee wed cea tensa eae ee 187 Introduction 5 ious tote eek Ave eta See ae ok patina ites i TD ae dna a SA 187 Fiber Optic Cable 4s cnet ceed ce A bs hana Pathan Ae et atts tage ane 188 140 CPU 671 60 Specifications for Modicon Quantum Hot Standby with NY sce Bikes veda alle ee aed RE ad PRA pode Pea wal ewe tack dG EEA 189 CRP Remote I O Head Processor Error Patterns 0000005 191 TENDS a a a e ee ee 193 Cis Meus A N r A E E E are eet nie an al al wal ee 195 sa at eatin astute uscd hk Scan Sse oe eh ates E ata Base tact ease estate Sew 211 Safety Information Important Information NOTICE Read these instructions carefully and look at the equipment to become familiar with the device before trying to install operate or maintain it The following special messages may appear throughout this documentation or on the equipment to warn of potential hazards or to call attention to information that clarifies or simplifies a procedure that an electrical hazard exists which will result in personal injury if the The addition of this symbol to a Danger or Warning safety label indicates instructions are not followed injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A DANGER DANGER indicates an imminently hazardous situation which if not avoided will result in death serious injury or equipment dama
141. tandby 46 Using IEC Logic and Modicon Quantum Hot Standby with Unity 3 Introduction Overview This chapter provides information about using IEC Logic with a Modicon Quantum Hot Standby with Unity system What s in this This chapter contains the following topics 2 Chapter Topic Page Modicon Quantum Hot Standby with Unity and IEC Logic 48 Understanding the Modicon Quantum Hot Standby with Unity State RAM 49 Transfer Process Understanding System Scan Time in Modicon Quantum Hot Standby with 50 Unity Systems Transferring Application Data in a Modicon Quantum Hot Standby with Unity 54 System 47 IEC Logic Modicon Quantum Hot Standby with Unity and IEC Logic Overview Data Transfer and User Data State RAM Definition A Modicon Quantum Hot Standby with Unity system requires two backplanes configured with identical hardware software and firmware One of the controllers PLC functions as the Primary controller and the other as a Standby controller e The Primary updates the Standby after every scan e The Primary and Standby communicate constantly monitoring the health of the system e Ifthe Primary fails the Standby takes control within one scan In a Modicon Quantum Hot Standby with Unity system data is transferred from Primary to Standby after every scan The following data transfers after every scan Located Variables State RAM 128 Kb al
142. tandby with Unity Copro attempt to detect hardware errors in the module before the application is allowed to run If the module fails any of its tests it will remain offline and will not communicate with the other Modicon Quantum Hot Standby with Unity module Run time tests are performed whenever the Copro is in the operational state Run time tests are executed in small slices to prevent delays in scan time If the module fails any of its tests the module remains offline and will not communicate with the other module 124 Maintaining a Modicon Quantum Hot Standby with Unity System Detecting and Diagnosing Failures in a Modicon Quantum Hot Standby with Unity System Important Information Understanding Health Messages Finding Diagnostic Information with Unity Pro Please note If Then Component of Primary fails Control shifts to Standby Component of Standby fails Standby goes offline Fiber optic cable link fails Standby goes offline The Primary sends a health message to the Standby every 10 milliseconds If Then Primary Sends Health Message No communication is required with any drop on RIO link every 5 milliseconds All systems OK every scan Exceptions If Then Standby never receives any message on either link 1 Standby determines cause of failure 2 Standby assumes control Primary does
143. te RAM you may have a maximum of 512 Kb of unlocated data The amount of data to be transferred is automatically adjusted by the system For Information on the size of the memory consumption select PLC gt Memory Consumption 54 Setting up and Maintaining a Modicon Quantum Hot Standby with Unity System At a Glance Purpose What s in this Part This part describes three important processes in using a Modicon Quantum Hot Standby with Unity system e setting up installing and cabling a Modicon Quantum Hot Standby with Unity system e configuring a Modicon Quantum Hot Standby with Unity system using the Unity Pro software e maintaining a Modicon Quantum Hot Standby with Unity system once installed This part contains the following chapters Chapter Chapter Name Page 4 Setting up Installing and Cabling a Modicon Quantum Hot 57 Standby with Unity System 5 Configuring a Modicon Quantum Hot Standby with Unity 69 System 6 Maintaining a Modicon Quantum Hot Standby with Unity 123 System 55 Maintaining Modicon Quantum Hot Standby with Unity 56 Setting up Installing and Cabling a Modicon Quantum Hot Standby 4 with Unity System Introduction Overview This chapter provides an overview of setting up installing and cabling a Modicon Quantum Hot Standby with Unity system What s in this This chapter contains the following t
144. te or Disable all Click button Button to control the events Start reStart Warm Start Click button To initialize Warm Start Cold Start Click button To initialize Cold Start Output fallback Applied Outputs N A Not used in Modicon Output Fallback N A Quantum Hot Standby with Unity system Last Stop Read only e Day Indicates the day e DD MM YY _ date time and cause e Time of the last controller stop Unity Pro Realtime clock tab dialog Hi Picscreen B m Task Realtime clock Information PLC Date and Time User Date and Time Tuesday 01 January 2002 El September 2003 Date 12 00 00 AM Sun Mon Tue Wed Thu Fri Sat 25 09 2203 E 3 1 2 3 4 5 6 PC Date and Time 7 8 9 10 11 12 13 Time 14 15 16 17 18 19 20 36 Thursday 25 September 2003 21 22 23 24 26 27 enb7eEM 2 38 05 PM 28 29 30 1 2 3 4 Update eee pie ee OE Update PC gt PLC O Today 9 25 2003 User gt PLC Error PLC Data 83 Configuring a Modicon Quantum Hot Standby with Unity System Describing the Realtime Clock Tab Viewing the Information Tab Description of the Realtime clock tab Item Option Description PLC Date and Time Read only Indicates the current PLC date and time PC Date and Time Update PC gt PLC Updates the PLC with the PC system time User Date and Time Update User gt PLC U
145. ter clarity when reading you can use the sign _ between bits Example 2 1111_1111 or 2 11111111 in decimal 255 2 1110_0000 or 2 11100000 in decimal 224 A literal value in base 8 is used to represent an octal integer The base is determined by the number 8 and the sign The signs and are not allowed For greater clarity when reading you can use the sign _ between bits Example 8 3_77 or 8 377 in decimal 255 8 34_0 or 8 340 in decimal 224 BCD is the abbreviation of Binary Coded Decimal format BCD is used to represent decimal numbers between 0 and 9 using a group of four bits half byte In this format the four bits used to code the decimal numbers have a range of unused combinations 197 Glossary Example of BCD coding e the number 2450 e is coded 0010 0100 0101 0000 BOOL BOOL is the abbreviation of Boolean type This is the elementary data item in computing A BOOL type variable has a value of either O FALSE or 1 TRUE A BOOL type word extract bit for example MW10 4 BYTE When 8 bits are put together this is callad a BYTE A BYTE is either entered in binary or in base 8 The BYTE type is coded in an 8 bit format which in hexadecimal ranges from 16 00 to 16 FF D DATE The DATE type coded in BCD in 32 bit format contains the following information DATE_AND_TIM E DBCD e the year coded in a 16 bit field e the month coded in an 8 bit field e the day coded i
146. th 124 125 130 133 No Standby 129 warning 193 mismatches checksums CKSM 135 logic 118 MOD buttons 23 Modbus 94 Modbus Plus 90 94 96 143 Modbus ports 81 Modbus RTU 143 modes Hot Standby 31 OFFLINE 115 118 RUN 115 modifications 150 160 offline 155 160 online 153 154 160 modules replacing 136 monitor RIO commands 134 monitor RIO requests 134 multiple transfer packets 165 multitasking restrictions 42 N No Standby commands 129 No Standby messages 129 NOE 16 58 98 102 109 189 NOM 16 58 213 Index NOR 62 not healthy communications 134 O offsets 94 network addresses 94 order Hot Standby 31 OSLoader 143 overhead system 51 P packets multiple transfers 165 PCMCIA cards 88 Peer Cop 75 PLC operations screens 30 Primary controllers time of day clocks 121 programs application 135 identical 135 146 transferring 164 168 R Rebuild All Project 146 red indicators 26 reference types 48 79 registers 41 71 command 114 135 reverse 41 status 117 remote I O networks 65 reports 125 requests Copro link 134 monitor RIO 134 reset buttons 22 restrictions DIO 43 local I O 43 multitasking 42 USB links 45 reverse registers 41 71 right buttons 23 28 RIO 63 heads 131 133 links 131 133 S S908 modules 40 scan times 49 50 114 124 125 127 128 130 135 148 sections data 148 SFC 48 151 updating 1
147. the Primary to the Standby during scans Because of the transfer process legacy Hot Standby systems could support different application programs in the two controllers One application program resided in one controller and a different application program resided in the other controller In the legacy system the user could program the logic now called application program and decide where to store the data With this method of programming the memory is known as static data memory layout and is necessary to have different user data accessing the same variables In the Modicon Quantum Hot Standby with Unity system all memory is allocated by a memory manager which automatically transfers the logical memory to a physical memory location This dynamic data memory layout is the heart of the programming flexibility and platform independence that Unity Pro provides but on a Modicon Quantum Hot Standby with Unity system with different user logic dynamic data memory layout makes a cyclical data update very difficult Therefore mismatches occur In a Modicon Quantum Hot Standby with Unity system Logic Mismatch allows the following without stopping the application program process e modify edit online an application program in the Standby while the Primary controls the process See Online Modifications to an Application Program in the Standby and Logic Mismatch p 153 e modify online an application program in the Primary while the Prim
148. the power of 32 1 Example 0 4294967295 24 11111111111111111111111111111111 8 37777777777 16 FFFFFFFF UINT UINT is the abbreviation of Unsigned integer format coded on 16 bits The lower and upper limits are as follows 0 to 2 to the power of 16 1 Example 0 65535 2 1111111111111111 8 177777 16 FFFF Unlocated An unlocated variable is a variable for which it is impossible to know its position in variable the PLC memory A variable which have no address assigned is said to be unlocated V Variable Memory entity of the type BOOL WORD DWORD etc whose contents can be modified by the program during execution WwW WORD The WORD type is coded in 16 bit format and is used to carry out processing on bit strings This table shows the lower upper limits of the bases which can be used 208 Glossary Base Lower limit Upper limit Hexadecimal 16 0 16 FFFF Octal 8 0 8 177777 Binary 2 0 2 1111111111111111 Representation examples Data content Representation in one of the bases 0000000011010011 16 D3 1010101010101010 8 125252 0000000011010011 2 11010011 209 Glossary 210 Index Symbols l 48 79 IW 48 79 M 79 MW 48 79 Q 48 SWEO 41 71 114 160 SWE61 41 71 118 SWE2 41 71 SW63 41 71 Numerics 16 bit compatibility 40 32 bit compatibility 40 984 Ladder Logic 72 A adapters self terminati
149. the same bit selected in Step 3 Set bit to 1 Note Ensure Standby displays RUN Standby Ensure the Primary and Standby controllers are in RUN Primary and RUN Standby mode 68 Configuring a Modicon Quantum Hot Standby with Unity System 5 Introduction Overview What s in this Chapter This chapter describes configuring the Modicon Quantum Hot Standby with Unity 140 CPU 671 60 module This chapter contains the following sections Section Topic Page 5 1 Configuring a System with the Unity Pro Tabs and Dialogs 70 5 2 Configuring a NOE with Unity Pro 99 5 3 Configuring Registers with Unity Pro 112 69 Configuring a Modicon Quantum Hot Standby with Unity System 5 1 Configuring a System with the Unity Pro Tabs and Dialogs At a Glance Purpose Use the Unity Pro editor dialog tabs to 1 select options for configuring the Modicon Quantum Hot Standby with Unity 140 CPU 671 60 2 obtain system status information This material describes how you can e Accessing the Base Configuration p 74 including Modbus Ports and HSBY e Configuring with Unity Pro p 88 e Configuring with Unity Pro p 90 What s in this This section contains the following topics Section Topic Page Introducing Unity Pro 71 Accessing the Base Configuration 74 Using the Summary Tab 75 Using the Overview Tab 76 Using the Confi
150. time Primary finds an empty Standby e using the keypad Use either the Primary or Standby The following table shows the Application Program Transfer Procedure Step Action 1 Ensure the Primary Controller is in RUN PRIMARY mode Result The LCD on the PLC will display the mode as RUN PRIMARY 2 Check that both 1 Invalidate Keypad option is NOT selected 2 the key switch is unlocked Go to the submenu Hot Standby Transfer Push Enter to execute the application program transfer from the Primary to the Standby 5 Note The Hot Standby Transfer command can be performed either in the Primary or Standby controller BUT only the Standby controller will be updated 168 Application Program Transfer Identical After the transfer the Primary and Standby have identical configurations and Configurations application programs and Application In the event of a failure in the Primary and depending on the mode selected for the Programs Standby Run or Offline the Standby may or may not be ready to assume the role of Primary 169 Application Program Transfer 170 Using the Modicon Quantum Hot Standby with Unity EFBs 1 0 Introduction Overview What s in this Chapter This chapter describes the Modicon Quantum Hot Standby with Unity elementary function blocks EFBs HSBY_RD HSBY_ST HSBY_WR REV_XFER This chapter contains the following topic
151. to the Primary NOE and then assigns the configured IP Address 1 to the Secondary NOE Offline Mode at Power up Sequence table Offline Mode at Power up Sequence Result Controller A powers up before controller B e IP Address of controller A is configured IP Address e P Address of controller B is the configured IP Address 1 Both controller A and controller B power up The resolution algorithm will assign controller A a the same time the configured IP address and will assign controller B the configured IP address 1 The NOE performs a duplicate IP test by issuing an ARP request to the configured IP Address If a response is received within 3 seconds the IP Address remains at the Default IP and blinks a diagnostic code If no IP configuration exists the NOE remains in standalone mode and the IP Address must be obtained from either a BOOTP server or from a MAC address 103 Configuring a Modicon Quantum Hot Standby with Unity System Power Up and Ethernet Services Modicon Quantum Hot Standby with Unity HSBY state The following table shows how the status of an NOE service is affected by the HSBY State Status of NOE Services Client Services Client Server Services Server Services I O Scanner Global Data Modbus FTP SNMP HTTP Messaging Unassigned Run Run Run Run Run Run Primary Run Run Run Run Run Run Secondary Stop Stop Run Run Run Run Offline St
152. troller is the only message received by the Standby RIO Head 2 Standby controller listens to the high speed data link for one scan 3 If Standby controller hears nothing Standby knows that the failure must be on both the Primary Copro and Primary CPU 4 Standby assumes control 132 Maintaining a Modicon Quantum Hot Standby with Unity System Detecting Remote I O RIO Link Failures Important Facts information 1 Remote I O RIO Link connects the two RIO Heads 2 Primary RIO Head performs a health check on the RIO link by sending health messages Primary RIO Head sends a health message every 5 milliseconds Unlike the health communication check performed on the Copro link the Primary Copro does not wait for a response from the Standby Copro Instead the Primary Copro expects a reply every second Expecting a reply every second minimizes the impact on the Primary s performance Standby How the Standby handles messages depends on Controller and If Standby Then Action Messages Never Responds to any Primary assumes that the Standby continues to message Standby RIO Head failed control the drops Never Receives a message Standby assumes failure may be Standby cannot from the Primary in the RIO link assume control 133 Maintaining a Modicon Quantum Hot Standby with Unity System Standby To start the process Monitors Rio and Step
153. type is ARRAY 0 5 OF Int You can find it in the libset in the same family than the EFs which use it ANL_IN is the abbreviation of Analog Input data type and is used when processing analog values The Iw adresses for the configured analog input module which were specified in the I O component list are automatically assigned data types and should therefore only be occupied with Unlocated Variables 195 Glossary ANL_OUT ANY ANL_OUT is the abbreviation of Analog Output data type and is used when processing analog values The mw adresses for the configured analog input module which were specified in the I O component list are automatically assigned data types and should therefore only be occupied with Unlocated Variables There is a hierarchy between the different types of data In the DFB it is sometimes possible to declare which variables can contain several types of values Here we use ANY_xxx types The following diagram shows the hierarchically ordered structure ANY ANY_ELEMENTARY IANY_MAGNITUDE_OR_BIT ANY_MAGNITUDE ANY_NUM ANY_REAL REAL ANY_INT DINT INT UDINT UINT TIME ANY_BIT DWORD WORD BYTE BOOL ANY_STRING STRING ANY_DATE DATE_AND_TIME DATE TIME_OF_DAY EBOOL ANY_DERIVED ANY_ARRAY ANY_ARRAY_ANY_EDT ANY_ARRAY_ANY_MAGNITUDE ANY_ARRAY_ANY_NUM NY_ARRAY_ANY_REAL ANY_ARRAY_REAL NY_ARRAY_ANY_INT ANY_ARRAY_DINT ANY_ARRAY_INT ANY_ARRAY_UDINT ANNY_ARRAY_UINT ANY_ARRAY_TIME A
154. um Hot Standby with Unity System i At a Glance Purpose This part introduces the Modicon Quantum Hot Standby with Unity system The content describes the hardware available the compatibility of Modicon Quantum Hot Standby with Unity system with legacy systems and using IEC logic and Unity What s in this This part contains the following chapters Rares Chapter Chapter Name Page 1 Modicon Quantum Hot Standby with Unity Overview 15 2 Modicon Quantum Hot Standby with Unity Compatibility 39 Differences and Restrictions 3 Using IEC Logic and Modicon Quantum Hot Standby with Unity 47 13 Introducing Modicon Quantum Hot Standby with Unity 14 Modicon Quantum Hot Standby with Unity Overview Introduction Overview What s in this Chapter In this chapter you will find a brief overview of the Modicon Quantum Hot Standby with Unity system the module and the indicators This chapter contains the following topics Topic Page Overview of the Modicon Quantum Hot Standby with Unity System 16 Modicon Quantum Hot Standby with Unity 140 CPU 671 60 Module Overview 18 Modicon Quantum Hot Standby with Unity System Overview 19 Modicon Quantum Hot Standby with Unity 140 CPU 671 60 Components 21 Operating the Modicon Quantum Hot Standby with Unity 140 CPU 671 60 23 Keypad Using the Modicon Quantum Hot Standby with Unity 140 CPU 671 60 LED 25 Indicators Us
155. um CPU Peer Cop Enabled Hot Standby Enabled Describing Summary tab Item Option Value Description CPU Name Model Quantum CPU N A Read Only Peer Cop Disabled Enabled Read Only Peer Cop Enabled if the function is valid in the Modbus Plus menu Hot Standby Enabled Enabled Read Only 75 Configuring a Modicon Quantum Hot Standby with Unity System Using the Overview Tab Viewing The read only Overview tab of the editor displays detailed information about the module s specifications 1 2 140 CPU 671 60 P266 CPU Hot Standby 1 Mb Program PCMCIA Ethernet HSBY Fiber optic USB MB MB General Specifications Communications ports 1 Modbus RS 232 1 Modbus Plus R 1 USB 1 Ethernet used Bus Current required Max number of NOM NOK CRP 811 and fil Over F Sum Conti MB Moab ff Anima aa Hot St FF VO objects P266 CPU MB MB USB ETHERNET HSBY 1024K IEC AND PCMCIA SPECIFICATIONS a Model 140 CPU 671 60 Description P266 CPU MB MB MMS modules supported any combination 6 Key switch Yes _ Processor A 4 gt 76 Configuring a Modicon Quantum Hot Standby with Unity System Using the Configuration Tab View
156. used to monitor the current machine status of the Primary and Register Standby Both the Primary and the Standby Offline have their own copy of the Status register The Status register is not transferred from Primary to Standby Each PLC must maintain its local Status Register based on the regular communication between the two controllers The following illustration identifies the operating options provided by the Status Register This PLC in OFFLINE mode 0 1 This PLC running in primary mode 1 0 This PLC running in standby mode 1 1 Other PLC in OFFLINE mode 0 1 Other PLC running in primary mode 1 0 Other PLC running in standby mode 1 1 PLCs have matching logic 0 PLCs do not have matching logic 1 This PLC s switch set to A 0 This PLC s switch set to B 1 MSB 15 14 13 12 11 10 9 8 7 6 5 4 1 3 2 1 JO LSB i 0 Unlocated Variables being transferred Primary to Standby 1 Unlocated Variables not being transferred Primary to Standby 0 The hot standby has not been activated 1 The hot standby is active 117 Configuring a Modicon Quantum Hot Standby with Unity System System Words SW61 0 to SW61 3 System Word SW61 4 System Word SW61 5 System Word SW61 14 System Word SW61 15 These four bits display the states of the local and remote Hot Standby controllers Status of local PLC e S
157. ut module during your initial start up Before performing a switchover connect to the Primary and force the output bits in the module Perform the switchover and take note of the bumpless switchover effect on the forced bits Switchover Test To force a switchover using the front panel keypad do the following Action Access the front panel keypad of the Primary controller Go to PLC Operation menu Go to Hot Standby submenu Go to Hot Standby mode Modify Run to Offline Note Ensure that Standby switched to Primary Using Front Panel Keypad Step 1 2 3 4 5 6 Modify offline to run Note Ensure that the LCD displays Run Standby 67 Installation and Cabling Switchover Test Using Command Register Follow these steps Step Action 1 Connect to the Primary 2 Observe whether the controller order on the Primary is A or B Note Observe using either of the following methods e Front panel keypad of the Primary PLC Operation Hot Standby Hot Standby Order e Unity Pro status dialog Refer to the bottom of the Unity Pro window when connected online Access the Command Register system bit e SW60 1 If the connected Primary order is A e SWE60 2 If the connected Primary order is B Set bit to 0 Note Ensure that the Standby switched to Primary Connect to the new Primary Access the Command Register system bit Choose
158. viation of Double Word The DWORD type is coded in 32 bit format This table shows the lower upper limits of the bases which can be used Base Lower limit Upper limit Hexadecimal 16 0 16 FFFFFFFF Octal 8 0 8 37777777777 Binary 2 0 2 11111111111111111111111111111111 Representation examples Data content Representation in one of the bases 00000000000010101101110011011110 16 ADCDE 00000000000000010000000000000000 8 200000 00000000000010101011110011011110 2 10101011110011011110 E EBOOL EBOOL is the abbrevation of Extended Boolean type It can be used to manage rising or falling edges as well as forcing An EBOOL type variable takes up one byte of memory EF Is the abbreviation of Elementary Function This is a block which is used in a program and which performs a predefined software function 200 Glossary A function has no internal status information Multiple invocations of the same function using the same input parameters always supply the same output values Details of the graphic form of the function invocation can be found in the Functional block instance In contrast to the invocation of the function blocks function invocations only have a single unnamed output whose name is the same as the function In FBD each invocation is denoted by a unique number via the graphic block this number is automatically generated and can not be altered You position
159. xample Modicon Quantum NOMs NOEs 6 Note The sequence of the modules on the backplane is not predefined but the sequence of the modules on the backplanes of the Primary and the Standby must be identical Otherwise a Modicon Quantum Hot Standby with Unity system does not exist The following graphic shows a possible scheme for components and their connectors JL JL gt a Soc ecg r J7 W 1 Primary controller backplane 2 Standby controller backplane 3 Modicon Quantum Hot Standby with Unity 140 CPU 671 60 with integrated coprocessor Copro 4 Modicon Quantum power supply module Install power supply in first slot for better rack layout 5 Modicon Quantum RIO head 6 Other modules for example Modicon Quantum NOMs NOEs 7 Fiber Optic Cable to connect to both Modicon Quantum Hot Standby with Unity 140 CPU 671 60s 8 Coaxial cable with splitters 8A for connecting the RIO heads 5 with the RIO drops in the network The dashed connection represents a redundant connection in the RIO network which is not required for the Modicon Quantum Hot Standby with Unity system 9 Connection to the Unity Pro computer via Modbus or Modbus Plus 61 Installation and Cabling Connecting Two Modicon Quantum Hot Standby with Unity HE CPU 671 60s Handling Cable Connections Connecting Two Backplane

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